Battery and battery pack

ABSTRACT

A battery and a battery pack that includes the battery are provided. The battery includes a positive electrode including a positive electrode active material and a first current collector; a negative electrode including a negative electrode active material and a second current collector; a separator; a fluidic electrolyte; and a polymer layer including a polymeric material; wherein at least a portion of the polymer layer is provided between the separator and at least one of the positive electrode active material and the negative electrode active material; and wherein the fluidic electrolyte is provided in at least a void portion adjacent to at least one of the first current collector and the second current collector.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.14/643,419, filed Mar. 10, 2015, which is a continuation of U.S.application Ser. No. 13/748,059, filed on Jan. 23, 2013, now U.S. Pat.No. 8,986,893, issued on Mar. 24, 2015, which claims priority toJapanese Priority Patent Application JP 2012-014502 filed in the JapanPatent Office on Jan. 26, 2012, the entire content of each of which ishereby incorporated by reference.

BACKGROUND

The present disclosure relates to a battery, a battery pack, anelectronic apparatus, an electrically driven vehicle, an electricalstorage device, and an electric power system.

In recent years, portable electronic apparatuses such ascamera-integrated VTRs (Video Tape Recorder), cellular phone, andnotebook PCs have become widespread, and a reduction in size, weight,and thickness, and a longer operational lifespan have been stronglydesired. Along with this, the development of a battery as a powersupply, particularly, a secondary battery, which is light in weight, andwhich can obtain a high energy density, has been progressed.

Among these, a secondary battery (a so-called lithium ion secondarybattery) using occlusion and emission of lithium (Li) in a charge anddischarge reaction may obtain an energy density higher than that of alead battery or a nickel cadmium battery, and thus has been greatlyanticipated. As this secondary battery, a laminated film type battery inwhich an electrode body is packaged with a laminated film to realize areduction in weight and thickness has been widely used.

This laminated film type battery is light and thus energy density islarge. However, accompanying deformation of an exterior packaging memberdue to gas generation or the like inside the battery, liquid leakage orthe like becomes problematic in a case where an electrolyte composed ofa fluidic electrolyte similar to an electrolytic solution in the relatedart is used. As a method of solving this problem, using of a non-fluidicelectrolyte has attracted attention in the laminated film type battery.In a battery using the non-fluidic electrolyte, the liquid leakage isless concerned and stability increases, and thus there is an advantagein that a light and thin material such as an aluminum laminated film maybe used for an exterior packaging member.

However, in recent electronic apparatuses, since there is a tendency forhigh-performance and multi-function to further progress, charging anddischarging of the secondary battery is frequently repeated, and thuscharge and discharge capacity has a tendency to decrease. Particularly,deterioration is significant in a low-temperature environment, and thusan improvement in the battery characteristics is further desired. Inaddition, in electrical storage usage for a vehicle or electric powerequalization, the battery may be used in an environment in which anambient temperature is low, and thus an improvement in batterycharacteristic is desired.

In the secondary battery using the non-fluidic electrolyte, thesecharacteristics are particularly problematic. That is, in theelectrolytic solution having fluidity of the related art, migration ofions in a liquid becomes easy. Conversely, ion conductivity decreases inthe non-fluidic electrolyte due to the viscosity thereof. In addition,in a case where a highly deformable exterior packaging material is usedfor the laminated film, there is a problem in that an electrode body hasa tendency to deform, and thus adhesiveness between electrodesdecreases, and a battery characteristic further deteriorates. Thistendency becomes more significant in a battery using a laminatedelectrode body in which sheet-shaped electrodes are laminated.

To improve this performance, Japanese Unexamined Patent ApplicationPublication Nos. 08-511274 and 2009-70636 suggest a technology of usingionic liquid (bis(fluorosulfonyl) imide or the like is used as an anion)as an electrolytic solution. Japanese Unexamined Patent ApplicationPublication Nos. 08-511274 and 2009-70636 disclose a method in whichcharge transfer resistance in a battery is decreased by using theelectrolytic solution, and thus an output characteristic and a cyclecharacteristic of a battery are improved.

In addition, Japanese Unexamined Patent Application Publication Nos.2004-165151 and 2010-129449 disclose a technology of using anelectrolyte in which a compound that forms a film called an SEI (SolidElectrolyte Interface) on an electrode during charging and dischargingof a battery at an initial period of use is added into a solvent inadvance. Japanese Unexamined Patent Application Publication Nos.2004-165151 and 2010-129449 disclose a method in which an electrodesurface is stabilized by forming the SEI on the electrode, and thus adecrease in the output characteristic and the cycle characteristic of abattery is suppressed.

SUMMARY

However, in the electrolyte including the electrolyte salt disclosed inJapanese Unexamined Patent Application Publication Nos. 08-511274,2009-70636, 2004-165151 and 2010-129449, the battery characteristic isimproved to a certain degree, but it is necessary to further improve theproblem of a decrease of the above-described battery characteristic in acase where increasingly high capacity is attempted in the future.Particularly, this phenomenon becomes significant in long-term use, anduse in a high-temperature environment or a low-temperature environment,resulting in a further deterioration of the battery characteristic dueto a decrease in ion conductivity.

It is desirable to provide a battery in which a decrease in batterycharacteristic may be suppressed in long-term use, or use in ahigh-temperature environment or a low-temperature environment. Inaddition, it is desirable to provide a battery pack, an electronicapparatus, an electrically driven vehicle, an electrical storage device,and an electric power system that use the battery.

According to an embodiment of the present disclosure, there is provideda battery including a positive electrode, a negative electrode, and anelectrolyte including a fluidic electrolyte and a non-fluidicelectrolyte, the fluidic electrolyte configured to be imaged as a voidimage in a secondary electron image and a reflection electron imageobtained by energy dispersive X-ray spectroscopy, and the non-fluidicelectrolyte configured to be imaged in the secondary electron image andthe reflection electron image with a non-fluidic electrolyte contrastdifferent from a contrast associated with a member selected from thegroup consisting of a solid current collector, an active material, aconductive material, a binding material and a separator.

In the battery of the present disclosure, it is preferable that thenon-fluidic electrolyte be present between the positive electrode andthe negative electrode, the fluidic electrolyte be present at least in avoid inside active material layers of the positive electrode and thenegative electrode. It is more preferable that the fluidic electrolytebe present between the positive electrode and the negative electrode.

In the battery of the present disclosure, it is preferable that a porousseparator be interposed between the positive electrode and the negativeelectrode, and the non-fluidic electrolyte be present between at leastone of the positive electrode and the negative electrode, and theseparator.

In the battery of the present disclosure, it is preferable that theelectrolyte salt contain an imide salt compound expressed by Chem. 1.Particularly, it is preferable that the electrolyte salt be an imidesalt compound expressed by Chem. 1 in which at least one Z is a fluorineatom.M⁺[(ZY)₂N]⁻  (Chem. 1)

(here, M⁺ represents a monovalent cation, Y represents SO₂ or CO, and Zindependently represents a fluorine atom or a polymerizable functionalgroup).

In the battery of the present disclosure, it is preferable that a volumeratio of the non-fluidic electrolyte in the electrolyte be 0 to 6 vol %.

In the battery of the present disclosure, it is preferable that aweight-average molecular weight of the polymeric material be 500,000 ormore.

In the battery of the present disclosure, it is preferable that thepositive electrode active material be a lithium composite phosphatehaving an olivine type structure expressed by Chem. I,Li_(a)M1_(b)PO₄  (Chem. I)

(here, M1 represents at least one kind of element selected from elementsof group II to group XV, and a and b represent values within ranges of0≦a≦2.0 and 0.5≦b≦2.0).

A battery pack, an electronic apparatus, an electrically driven vehicle,an electrical storage system, and an electrical power system of thepresent disclosure include the above-described battery.

According to the present disclosure, it is possible to provide a batteryin which a non-fluidic electrolyte improves adhesiveness betweenelectrodes, the fluidic electrolyte maintains high ion conductivity, andthus high battery characteristic may be maintained even in ahigh-temperature environment or a low-temperature environment.

Additional features and advantages are described herein, and will beapparent from the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a secondary electron image of an electrode body, in which thesecondary electron image is obtained by an energy dispersive X-rayspectroscopy (SEM-EDX) and illustrates a state of non-fluidicelectrolyte and electrolytic solution of the present disclosure of across-section;

FIGS. 2A to 2C are exterior perspective views and an explodedperspective view illustrating a configuration a laminated film typebattery using a laminated electrode body according to a first embodimentof the present disclosure;

FIG. 3 is a cross-sectional view illustrating a part of the laminatedelectrode body, which is accommodated in the battery shown in FIG. 2B,in an enlarged manner;

FIGS. 4A and 4B are perspective views illustrating a positive electrodeand a negative electrode that are used in the laminated electrode bodyaccommodated in the battery illustrated in FIG. 2B;

FIG. 5 is an exploded perspective view illustrating a configuration of alaminated film type battery using a wound electrode body according tothe second embodiment of the present disclosure;

FIG. 6 is a cross-sectional view illustrating the wound electrode bodyaccommodated in the battery illustrated in FIG. 5;

FIG. 7 is a schematic view illustrating a configuration of a squarebattery according to a third embodiment of the present disclosure;

FIG. 8 is a cross-sectional view illustrating a configuration acylindrical battery according to a fourth embodiment of the presentdisclosure;

FIG. 9 is a block diagram illustrating a circuit configuration exampleof a battery pack according to a fifth embodiment of the presentdisclosure;

FIG. 10 is a schematic diagram illustrating an example in whichapplication is made to an electrical storage system for a houseaccording to a sixth embodiment of the present disclosure; and

FIG. 11 is a schematic diagram illustrating an example of aconfiguration of a hybrid car adopting a series hybrid system to whichthe present disclosure is applied.

DETAILED DESCRIPTION

Hereinafter, preferred embodiments (hereinafter, referred to asembodiment) for carrying out the present disclosure will be described.In addition, the description will be made as follows.

1. First Embodiment (Example of Electrolyte of the Present Disclosure)

2. Second Embodiment (Example of Laminated Film Type Battery UsingElectrolyte of Present Disclosure)

3. Third Embodiment (Example of Square Battery Using Electrolyte ofPresent disclosure)

4. Fourth Embodiment (Example of Cylindrical Battery Using Electrolyteof Present disclosure)

5. Fifth Embodiment (Example of Battery Pack Using Electrolyte ofPresent disclosure)

6. Sixth Embodiment (Example of Electrical Storage System Using Battery,or the like)

1. First Embodiment

In this first embodiment, an electrolyte of the present disclosure willbe described.

The electrolyte of the present disclosure includes: a fluidicelectrolyte in which an electrolytic solution containing a solvent andan electrolyte salt is present while maintaining fluidity, and anon-fluidic electrolyte in which an electrolytic solution containing asolvent and an electrolyte salt is supported by a polymeric material. Inthe electrolyte of the present disclosure, the non-fluidic electrolytemay be present between the positive electrode and the negative electrodemaking up the battery, and the fluidic electrolyte may be present atleast in a void inside active material layers of the positive electrodeand the negative electrode. It is preferable that the fluidicelectrolyte be present between the positive electrode and the negativeelectrode. In addition, a porous separator may be interposed between thepositive electrode and the negative electrode, and the non-fluidicelectrolyte may be present between at least one of the positiveelectrode and the negative electrode, and the separator. In addition,the fluidic electrolyte may be an electrolytic solution that is obtainedby eluting a part of the polymeric material contained in the non-fluidicelectrolyte. Even when the electrolytic solution contains the polymericmaterial, in a case where fluidity is maintained, the electrolyticsolution is regarded as the fluidic electrolyte.

In the battery of the present disclosure, both of the fluidicelectrolyte and the non-fluidic electrolyte are present as anelectrolyte. Therefore, the non-fluidic electrolyte brings the positiveelectrode and the negative electrode into close contact with each other.As a result, deformation of the electrodes is suppressed, a decrease inbattery reactivity between the positive electrode and the negativeelectrode is suppressed, a fluidized electrolyte maintains high ionconductivity in the electrolyte due to fluidity thereof. Furthermore,since the non-fluidic electrolyte brings the positive electrode and thenegative electrode into close contact with each other, deformation ofthe electrodes due to expansion and contraction accompanying chargingand discharging is not likely to occur, and a decrease in batteryreactivity due to a decrease in adhesiveness between the positiveelectrode and the negative electrode may be suppressed.

In the electrolyte of the present disclosure, it is preferable that avolume ratio of the non-fluidic electrolyte layer be 0 to 6 vol % on thebasis of the total volume of the entire electrolytes, that is, thenon-fluidic electrolyte layer and the fluidic electrolyte. Due to this,high ion conductivity due to the fluidic electrolyte and theadhesiveness between electrodes due to the non-fluidic electrolyte layermay be obtained in a relatively appropriate manner.

In addition, in the electrolyte of the present disclosure, it ispreferable that a volume ratio of the polymeric material be 0 to 0.3 vol% on the basis of the total pore volume of the positive electrode, thenegative electrode, and the separator.

In addition, the non-fluidic electrolyte layer and the fluidicelectrolyte, which are formed in the battery, of the present disclosuremay be analyzed, for example, in such a manner that after the battery isdisassembled to take out an electrode body including the positiveelectrode and the negative electrode, the contrast of a SEM image suchas a secondary electron image and a reflection electron image of across-section of the electrode body is analyzed by an energy dispersiveX-ray spectroscopy (SEM-EDX).

In a case of confirming the volume ratio of the non-fluidic electrolytelayer from the contrast of the secondary electron image and thereflection electron image of the cross-section of the electrode body,for example, an area ratio of an area of the non-fluidic electrolyte andan area of the fluidic electrolyte is calculated from the SEM image,which is obtained by the energy dispersive X-ray spectroscopy (SEM-EDX),or the like, and this area ratio may be set as a volume ratio of thenon-fluidic electrolyte and the fluidic electrolyte. As shown in FIG. 1,in the secondary electron image and the reflection electron image, anelectrolytic solution that is a liquid fluidic electrolyte is notphotographed actually as an image, and is confirmed as a void portion(that is, a void portion of the active material layer) between the solidcurrent collector, the active material, and a conductive material or abinding material, or as a vacant portion of the separator. In addition,the semi-solid non-fluidic electrolyte is expressed with a contrastdifferent from that of the solid current collector, the active material,the conductive material or a binding material, or the separator.

In addition, the formation ratio of the non-fluidic electrolyte layerand the fluidic electrolyte may be analyzed by performing an elementanalysis of the electrolytes using an element analysis method in therelated art, that is, the energy dispersive X-ray spectroscopy (SEM-EDX)or the like. In a case of using this method, so as to preventunnecessary components in the electrolyte from being unintentionallyanalyzed, it is preferable that the analysis be performed after cleaningthe surface of the electrodes with an organic solvent such as dimethylcarbonate (DMC).

Electrolytic Solution

An electrolytic solution includes a solvent and an electrolyte salt.

As the solvent, for example, a non-aqueous solvent may be used. Examplesof the non-aqueous solvent include ethylene carbonate (EC), propylenecarbonate (PC), butylene carbonate, dimethyl carbonate, diethylcarbonate, ethyl methyl carbonate, methyl propyl carbonate,γ-butyrolactone, γ-valerolactone, 1,2-dimethoxyethane, tetrahydrofuran,2-methyltetrahydrofuran, tetrahydropyran, 1,3-dioxolane,4-methyl-1,3-dioxolane, 1,3-dioxane, 1,4-dioxane, methyl acetate, ethylacetate, methyl propionate, ethyl propionate, methyl butyrate, methylisobutyrate, methyl trimethylacetate, ethyl trimethylacetate,acetonitrile, glutaronitrile, adiponitrile, methoxyacetonitrile,3-methoxypropionitrite, N,N-dimethylformamide, N-methylpyrrolidinone,N-methyloxazolidinone, N,N′-dimethylimidazolidinone, nitromethane,nitroethane, sulfolane, trimethyl phosphate, dimethyl sulfoxide, and thelike. These may be used alone or plural kinds thereof may be mixed andused.

Among these, it is preferable to use at least one selected from a groupconsisting of ethylene carbonate, propylene carbonate, dimethylcarbonate, diethyl carbonate and ethyl methyl carbonate as thenon-aqueous solvent. In this case, particularly, it is preferable to usea combination of a high viscosity (high dielectric constant) solvent(for example, specific dielectric constant ∈≧30) such as ethylenecarbonate and propylene carbonate and a low viscosity solvent (forexample, viscosity ≦1 mPa·s) such as dimethyl carbonate, diethylcarbonate and ethyl methyl carbonate. This is because dissociation andion mobility of the electrolyte salt are improved and thus a relativelysuperior effect may be obtained.

As the electrolyte salt, one or more kinds of light metal salts such asa lithium salt may be contained. Examples of the lithium salt includelithium hexafluorophosphate (LiPF₆), lithium tetrafluoroborate (LiBF₄),lithium perchlorate (LiClO₄), lithium hexafluoroarsenate (LiAsF₆),lithium tetraphenylborate (LiB(C₆H₅)₄), lithium methanesulfonate(LiCH₃SO₃), lithium trifluoromethane sulfonate (LiCF₃SO₃), lithiumtetrachloroaluminate (LiAlCl₄), dilithium hexafluorosilicate (Li₂SiF₆),lithium chloride (LiCl), lithium bromide (LiBr), and the like. Amongthese, at least one selected from a group consisting of lithiumhexafluorophosphate, lithium tetrafluoroborate, lithium perchlorate, andlithium hexafluoroarsenate is preferable, and lithiumhexafluorophosphate and lithium tetrafluoroborate are more preferable.

As the electrolyte salt, an imide salt compound expressed by Chem. 1 tobe described below may be contained. The imide salt compound has aspecial merit in that the imide salt is not likely to be decomposed in ahigh-temperature environment. Therefore, it is preferable to use theimide salt compound as the electrolyte salt from the viewpoint that adecrease in battery characteristic during use in the high-temperatureenvironment or during use after being stored in the high-temperatureenvironment may be suppressed.

In addition, when being subjected to a high-temperature non-fluidizationtreatment during formation, the non-fluidic electrolyte may increaseadhesiveness between electrodes. Therefore, when the high-temperaturetreatment is performed during formation of the non-fluidic electrolyte,it is preferable to use the imide salt compound that is not likely to bedecomposed under the high-temperature environment as the electrolytesalt. As a result, the adhesiveness between electrodes may be increasedwithout causing a decrease in battery reactivity due to decomposition ofthe imide salt compound.M⁺[(ZY)₂N]⁻  (Chem. 1)

(here, M⁺ represents a monovalent cation, Y represents SO₂ or CO, andeach substituent group Z independently represents a fluorine atom or apolymerizable functional group.)

Examples of the cation ion making up M⁺ include alkali metal ions suchas a lithium ion (Li⁺), a sodium ion (Na⁺), and a potassium ion (K⁺),other metallic element ions, an ammonium cation, a phosphonium cation,and the like. Among these, the lithium ion is preferable.

Examples of the imide salt compound expressed in Chem. 1 include variousimide salt compounds such as lithium bis(fluorosulfonyl)imide, lithium(fluorosulfonyl)(trifluoromethylsulfonyl)imide, and lithiumbis(trifluoromethyl sulfonyl)imide.

Furthermore, as the imide salt compound, it is preferable to use acompound in which at least one substituent group Z in Chem. 1 is afluorine atom (it may be perfluorinated). This is because relativelysuperior battery characteristics are obtained. Examples of the imidesalt compound include lithium bis(fluorosulfonyl)imide,lithium(fluorosulfonyl)(trifluoromethyl sulfonyl)imide,lithium(fluorosulfonyl)(pentafluoroethyl sulfonyl)imide,lithium(fluorosulfonyl)(nonafluorobutyl sulfonyl)imide,lithium(fluorosulfonyl)(phenyl sulfonyl)imide,lithium(fluorosulfonyl)(pentafluorophenyl sulfonyl)imide,lithium(fluorosulfonyl)(vinyl sulfonyl)imide, and the like. These imidesalt compounds may be used alone or two or more kinds thereof may bemixed and used. Here, the imide salt compound in Chem. 1 is not limitedto these imide salt compounds.

The content of the electrolyte salt in the electrolytic solution ispreferably 0.6 to 2.0 mol/kg with respect to the solvent, and morepreferably 0.6 to 1.5 mol/kg. This is because high ion conductivity maybe obtained.

Non-Fluidic Electrolyte

The non-fluidic electrolyte may be composed of a completely solid typeelectrolyte formed from a solid having ion conductivity, but it ispreferable to use a semi-solid electrolyte that is non-fluidized while apolymeric material supports the electrolytic solution. In this case, asthe electrolytic solution that is supported by the polymeric material,the above-described electrolytic solution may be used.

A mass ratio of the electrolytic solution that is supported in thenon-fluidic electrolyte is preferably 90 to 99 mass % or less withrespect to the non-fluidic electrolyte. In addition, in regard to theelectrolyte of the present disclosure, which is present between thepositive electrode and the negative electrode as described, the volumeratio of the polymeric material is preferably 0 to 0.3 vol % on thebasis of the total void volume of the positive electrode, the negativeelectrode, and the separator, but when considering the specific gravityof the polymeric material, the mass ratio of the electrolytic solutionthat is supported in the non-fluidic electrolyte corresponds to theabove-described range. In a case where the amount of the electrolyticsolution that is supported in the non-fluidic electrolyte is excessive,an effect sufficient for maintenance of the battery shape due to closecontact between electrodes may not be obtained. In a case where theamount of the electrolytic solution that is supported in the non-fluidicelectrolyte is insufficient, ion conductivity in the non-fluidicelectrolyte becomes insufficient, and thus there is a concern that thebattery characteristics may decrease.

As the polymeric material, various materials may be used, but there arepolymeric materials, which are preferably and appropriately used,respectively, in accordance with methods of forming a layer of thenon-fluidic electrolyte. Therefore, a method of forming the non-fluidicelectrolyte layer will be described.

As the method of forming the non-fluidic electrolyte layer, a method ofsubjecting an electrolytic solution or a semi-solid electrolyteprecursor to non-fluidization treatment is preferably used. Preferableexamples of the method include (1) a method of impregnating theelectrolytic solution into the polymeric material at normal temperatureor in a heated state, (2) a method of performing a polymerizationtreatment such as ultraviolet curing or thermal curing with respect tothe electrolytic solution containing the polymeric material present as apolymeric gelling agent, and (3) a method in which a material obtainedby melting the polymeric material in the electrolytic solution at a hightemperature is cooled to normal temperature, and the like. In a case ofusing the method (2) or (3), the electrolytic solution is furtherinjected after forming the non-fluidic electrolyte layer, and thus it ispossible to realize the battery configuration of the present disclosure,in which both of the non-fluidic electrolyte and the fluidic electrolyteare present.

In addition, details of the method of forming the non-fluidicelectrolyte layer will be described later in combination with a methodof manufacturing the battery.

In a case of using the method (1) of impregnating electrolyte into thepolymeric material at normal temperature or in a heated state, as thepolymeric material, a material that absorbs a solvent and gels ispossible. Examples of the polymeric material include a fluorine-basedpolymeric material such as a copolymer containing polyvinylidenefluoride or vinylidene fluoride, and hexafluoropropylene as a component;an ether-based polymeric material such as a polyethylene oxide and across-linking body containing polyethylene oxide; an alkyleneoxide-based polymeric material having an alkylene oxide unit; apolymeric material containing polyacrylonitrile, polypropylene oxide, orpolymethyl methacrylate as a repetitive unit; and the like. One kind ofthese polymeric materials may be used alone, or two or more kindsthereof may be mixed and used.

Particularly, from a viewpoint of redox stability, the fluorine-basedpolymeric materials are preferable, and among these, polyvinylidenefluoride is preferable. This is because in a process of non-fluidizationwith the electrolytic solution, swelling or dissolution is not likely tooccur, the polyvinylidene fluoride is advantageous for localization ofthe non-fluidic electrolyte layer, and the polyvinylidene fluoride isstrongly adhered to the positive electrode or the negative electrodeafter the non-fluidization of the electrolytic solution and thus abattery shape may be maintained. From the same viewpoint, aweight-average molecular weight of the polymeric material is preferably500,000 or more.

In addition, the weight-average molecular weight of the polymericmaterial may be measured by, for example, a gel permeationchromatography (GPC) method, a viscoelasticity measuring method, a meltflow rate (MFR) measuring method, an optical scattering method, and asedimentation velocity method, and the like.

Furthermore, the copolymer may contain a monoester of an unsaturateddibasic acid such as monomethyl maleic acid ester, a halogenatedethylene such as ethylene trifluoride chloride, a cyclic carbonate esterof an unsaturated compound such as vinylene carbonate, an epoxygroup-containing acrylic vinyl monomer, or the like as a component. Thisis because relatively superior characteristics may be obtained.

In a case of using the method (2) of performing a polymerizationtreatment such as ultraviolet curing or thermal curing with respect tothe electrolytic solution containing the polymeric material present as apolymeric gelling agent, examples of the polymeric gelling agent includecompounds having an unsaturated double bond such as an acryloyl group, amethacryloyl group, a vinyl group, and an allyl group. Specifically,examples of the polymeric gelling agent include acrylic acid, methylacrylate, ethyl acrylate, ethoxyethyl acrylate, methoxyethyl acrylate,ethoxyethoxyethyl acrylate, polyethylene glycol monoacrylate,ethoxyethyl methacrylate, methoxyethyl methacrylate, ethoxyethoxyethylmethacrylate, polyethylene glycol monomethacrylate,N,N-diethylaminoethyl acrylate, N,N-dimethylaminoethyl acrylate,glycidyl acrylate, allyl acrylate, acrylonitrile, N-vinylpyrrolidone,diethylene glycol diacrylate, triethylene glycol diacrylate,tetraethylene glycol diacrylate, polyethylene glycol diacrylate,diethylene glycol dimethacrylate, triethylene glycol dimethacrylate,tetraethylene glycol dimethacrylate, polyethylene glycol dimethacrylate,polyalkylene glycol diacrylate, polyalkylene glycol dimethacrylate, andthe like. Furthermore, examples of the polymeric gelling agent includetrifunctional monomers such as trimethylolpropane alkoxylate triacrylateand pentaerythritol alkoxylate triacrylate, and tetrafunctional ormulti-functional monomers such as pentaerythritol alkoxylatetetraacrylate and ditrimethylolpropane alkoxylate tetraacrylate. Amongthese, an oxyalkylene glycol-based compound having an acryloyl group ora methacryloyl group is preferable. Any one kind of the polymericgelling agents may be used alone, or two or more kinds thereof may bemixed and used.

A weight-average molecular weight of the polymeric material generatedfrom the polymeric gelling agent is preferably 500,000 or more. This isbecause the larger the weight-average molecular weight is, the furtherthe electrolytic solution has a tendency to be non-fluidized, and evenwhen being thin, a non-fluidic electrolyte layer having a high adhesionstrength with respect to the positive electrode or the negativeelectrode and the separator may be formed.

In a case of using the method (3) in which a material obtained bydissolving the polymeric material in the electrolytic solution at a hightemperature is cooled to normal temperature, any polymer compound may beused as long as it forms a gel with respect to the electrolytic solutionas a polymeric material and is stable as a battery material.Specifically, examples of the polymer compound include polymers having aring such as polyvinylpyridine and poly-N-vinylpyrrolidone; acrylatederivative-based polymers such as polymethylmethacrylate,polyethylmethacrylate, polybutylmethacrylate, polymethylacrylate,polyethylacrylate, polyacrylic acid, polymethacrylic acid andpolyacrylamide; fluorine-based resins such as polyvinyl fluoride andpolyvinylidene fluoride; CN group-containing polymers such aspolyacrylonitrile and polyvinylidene cyanide; polyvinyl alcohol-basedpolymers such as polyvinyl acetate and polyvinyl alcohol;halogen-containing polymers such as polyvinyl chloride andpolyvinylidene chloride; and the like. Any one kind of the polymericmaterials may be used alone, or two or more kinds thereof may be mixedand used. In addition, modified compounds, derivatives, randomcopolymers, alternating copolymers, graft copolymers, block copolymersof the polymeric materials, or the like may be used.

A weight-average of molecular weight of these polymeric materials ispreferably 500,000 or more. This is because the larger theweight-average molecular weight is, the further the electrolyticsolution has a tendency to be non-fluidized, and even when being thin, anon-fluidic electrolyte layer having a high adhesion strength with thepositive electrode or the negative electrode and the separator may beformed.

Effect

When the electrolyte of the first embodiment is used with respect to abattery, the battery characteristics during a use for a long-period oftime or during a use in a high-temperature environment or in alow-temperature environment may be improved.

That is, in the present disclosure, both of the fluidic electrolyte inwhich the electrolytic solution is present while maintaining fluidity,and the non-fluidic electrolyte in which the electrolytic solution issupported by the polymeric material are present in the battery.Therefore, adhesiveness between the positive electrode and the negativeelectrode increases due to the non-fluidic electrolyte, and the high ionconductivity may be maintained due to the fluidic electrolyte. Inaddition, when the imide salt compound is used as the electrolyte salt,decomposition of the electrolyte salt during charging and discharging orduring being stored in a high-temperature environment may be suppressed.In addition, since a non-fluidization treatment at a high temperaturemay be performed during formation of the non-fluidic electrolyte, anon-fluidic electrolyte layer having relatively high adhesiveness may beformed. In addition, when the imide salt compound is used as theelectrolyte salt, a decrease in battery characteristic in alow-temperature environment may be suppressed.

2. Second Embodiment

In this second embodiment, a configuration example of the battery usingthe electrolyte of the first embodiment will be described.

(2-1) First Configuration of Battery

A first configuration of the battery of the second embodiment is aso-called laminated film type battery in which a laminated electrodebody obtained by laminating electrodes is packaged by a laminated film.FIG. 2A shows an exterior perspective view seen from one main surfaceside of the battery 1 according to the second embodiment of the presentdisclosure, FIG. 2B shows an exploded perspective view seen from theother main surface side of the battery 1, and FIG. 2C shows an exteriorperspective view seen from the other main surface side of the battery 1.FIG. 3 shows a cross-sectional view illustrating a part of the laminatedstructure along a line III-III of the laminated electrode body 10 shownin FIG. 2B in an enlarged manner.

In this battery, the laminated electrode body 10, to which a positiveelectrode lead 2 and a negative electrode lead 3 are attached, is mainlypackaged by a film-shaped exterior packaging member 5. As shown in FIG.2B, the laminated electrode body 10, which is accommodated in thebattery 1, has a configuration in which a rectangular positive electrode11 and a rectangular negative electrode 12 are laminated with aseparator 13 interposed therebetween, the outermost circumferentialportion is protected by a fixing member 14 that is fixed thereto with aprotective tape. In addition, a non-fluidic electrolyte layer 15 isformed between the separator 13, and the positive electrode 11 andbetween the separator 13 and the negative electrode 12, respectively.The non-fluidic electrolyte layer 15 is, for example, a gelatinous layerin which an electrolytic solution is supported by a polymeric material.A battery structure using this film-shaped exterior packaging member 5is referred to as a laminated film type.

The positive electrode lead 2 and the negative electrode lead 3 lead outfrom the inside of the battery 1 packaged, for example, with theexterior packaging member 5 to the outside. The positive electrode lead2 is formed from, for example, a metallic material such as aluminum, andthe negative electrode lead 3 is formed from, for example, a metallicmaterial such as copper, nickel, and stainless steel. These metallicmaterials are formed, for example, in a thin plate shape or a networkshape.

Exterior Packaging Member

The exterior packaging member 5 is, for example, a laminated film thatis obtained by forming a resin layer on both surfaces of a metalliclayer. In the laminated film, an outer side resin layer is formed on asurface, which is exposed to the outside of the battery, of the metalliclayer, and an inner side resin layer is formed on a battery inner sidesurface, which is opposite to a power generating element such as thelaminated electrode body 10, of the metallic layer.

The metallic layer has an important function of blocking entrance ofmoisture, oxygen, and light to protect the contents, and aluminum (Al)is frequently used to form the metallic layer from the viewpoints oflightness, extensibility, price, and processing easiness. The outer sideresin layer has beauty in exterior appearance, toughness, flexibility,and the like, and a resin material such as nylon or polyethyleneterephthalate (PET) is used to form the outer side resin layer. Theinner side resin layer is a portion to be melted and fused with heat orultrasonic waves, and thus polyolefin is preferable for the inner sideresin layer, and casted polypropylene (CPP) is frequently used. Anadhesive layer may be provided between the metallic layer and the outerside resin layer and between the metallic layer and the inner side resinlayer, respectively, according to necessity.

In the exterior packaging member 5, a concave portion 5 a, which isformed, for example, by performing deep drawing in a direction towardthe outer side resin layer from the inner side resin layer andaccommodates the laminated electrode body 10, is provided, and the innerside resin layer is disposed to be opposite to the laminated electrodebody 10. Inner side resin layers, which are opposite to each other, ofexterior packaging member 5 are brought into close contact with eachother at outer edge portions of the concave portion 5 a by fusion or thelike. An adhesion film 4, which improves adhesiveness between the innerside resin layer of the exterior packaging member 5 and the positiveelectrode lead 2 and the negative electrode lead 3 that are formed froma metallic material, is disposed between the exterior packaging member 5and the positive electrode lead 2 and between the exterior packagingmember 5 and the negative electrode lead 3, respectively. The adhesionfilm 4 is formed from a resin material having a high adhesiveness with ametallic material. For example, the adhesion film 4 is formed from apolyolefin-based resin such as polyethylene, polypropylene, and modifiedpolyethylene or modified polypropylene that is modified from thepolyethylene and the polypropylene.

In addition, instead of an aluminum laminated film in which the metalliclayer is formed from aluminum (Al), the exterior packaging member 5 maybe formed from a laminated film having a different structure, apolymeric film such as polypropylene, or a metallic film.

The adhesion film 4, which prevents entrance of ambient air or moisture,is inserted between the exterior packaging member 5 and the positiveelectrode lead 2 and between the exterior packaging member 5 and thenegative electrode lead 3, respectively. The adhesion film 4 is formedfrom a material having adhesiveness with respect to the positiveelectrode lead 2 and the negative electrode lead 3. Examples of thismaterial include polyolefin resins such as polyethylene, polypropylene,modified polyethylene, and modified polypropylene.

Electrolyte

As shown in FIG. 3, a non-fluidic electrolyte layer 15 is formed, forexample, between the separator 13 and the positive electrode 11 andbetween the separator 13 and the negative electrode 12, respectively. Inaddition, an electrolytic solution (not shown) is injected into thebattery 1, and thus a fluidic electrolyte is present together with thenon-fluidic electrolyte layer 15. The non-fluidic electrolyte layer 15and the fluidic electrolyte are the same as those in the firstembodiment.

In addition, without using the separator 13, the non-fluidic electrolytelayer 15 may be used instead of the separator 13 that insulates thepositive electrode 11 and the negative electrode 12 and preventsphysical contact between the positive electrode 11 and the negativeelectrode 12. In this case, the non-fluidic electrolyte layer 15 isdisposed between the positive electrode 11 and the negative electrode12.

Positive Electrode

For example, each positive electrode 11 has a configuration in which apositive electrode active material layer 11B is provided on bothsurfaces of a positive electrode current collector 11A having a pair ofopposite surfaces, respectively. The positive electrode currentcollector 11A is formed from, for example, metallic foil such asaluminum foil. As shown in FIG. 4A, each positive electrode tab 11C,which is connected to the positive electrode lead 2, continuouslyextends from the positive electrode current collector 11A. Plural sheetsof the positive electrode tabs 11C, which extend from a plurality of thepositive electrodes 11 that are laminated, are fixed to each other andthe positive electrode current collector 11A is connected thereto. Inaddition, in FIG. 4A, so as to clarify the configuration of the positiveelectrode tab 11C, the positive electrode active material layer 11B isshown in a state in which a part thereof is not formed. However,actually, the positive electrode active material layer 11B is formed ata portion other than a portion of the positive electrode tab 11C.

The positive electrode active material layer 11B contains, for example,a positive electrode active material, a conductive material, and abinding material. The positive electrode active material layer 11Bcontains any one or more kinds of positive electrode materials, whichare capable of occluding and emitting lithium ions, as the positiveelectrode active material, and may contain other materials such as abinding material and a conductive material according to necessity.

Appropriate examples of the positive electrode material, which iscapable of occluding and emitting lithium ions, includelithium-containing compounds such as lithium oxide, lithium phosphorousoxide, lithium sulfide, and inter-layer compound containing lithium, andtwo or more kinds thereof may be mixed and used. So as to increaseenergy density, lithium-containing compounds including lithium, atransition metal element, and oxygen (O) are preferable. Examples ofthese lithium-containing compounds include lithium composite phosphatehaving an olivine type structure expressed by Chem. I, layered rock-salttype structure expressed by Chem. II, and the like. As thelithium-containing compound, compounds containing at least one kindselected from a group consisting of cobalt (Co), nickel (Ni), manganese(Mn), and iron (Fe) as a transition metal element are more preferable.Examples of these lithium-containing compounds include lithium compositephosphate having an olivine type structure expressed by Chem. III,lithium composite oxide having a layered rock-salt type structureexpressed by Chem. IV, Chem. V, or Chem. VI, lithium composite oxidehaving a spinel type structure expressed by Chem. VII, and the like.

Specifically, examples of these lithium-containing compounds includeLiNi_(0.50)Co_(0.20)Mn_(0.30)O₂, Li_(a)CoO₂ (a≈1), Li_(b)NiO₂ (b≈1),Li_(c1)Ni_(c2)Co_(1-c2)O₂ (c1≈1, 0<c2<1), Li_(d)Mn₂O₄ (d≈1), Li_(e)FePO₄(e≈1), and the like.Li_(a)M1_(b)PO₄  (Chem. I)

(Here, M1 represents at least one kind of element selected from elementsof group II to group XV, and a and b represent values within ranges of0≦a≦2.0 and 0.5≦b≦2.0.)Li_(c)Ni_((1-d-e))Mn_(d)M2_(e)O_((1-f))X_(g)  (Chem. II)

(Here, M2 represents at least one kind of element selected from elements(excepting nickel (Ni) and manganese (Mn)) of group II to group XV. Xrepresents at least one kind of element selected from elements(excepting oxygen (O)) of group XVI and group XVII. c, d, e, f, and grepresent values within ranges of 0≦c≦1.5, 0≦d≦1.0, 0≦e≦1.0,−0.10≦f≦0.20, and 0≦g≦0.2.)Li_(h)M3PO₄  (Chem. III)

(Here, M3 represents at least one kind selected from a group consistingof cobalt (Co), manganese (Mn), iron (Fe), nickel (Ni), magnesium (Mg),aluminum (Al), boron (B), titanium (Ti), vanadium (V), niobium (Nb),copper (Cu), zinc (Zn), molybdenum (Mo), calcium (Ca), strontium (Sr),tungsten (W), and zirconium (Zr). h represents a value within a range of0.9≦h≦1.1. In addition, the composition of lithium is differentdepending on the charge and discharge state, and the value of zrepresents a value in a completely discharged state.)Li_(i)Mn_((1-j-h))Ni_(j)M4_(k)O_((1-m))F_(h)  (Chem. IV)

(Here, M4 represents at least one kind selected from a group consistingof cobalt (Co), magnesium (Mg), aluminum (Al), boron (B), titanium (Ti),vanadium (V), chrome (Cr), iron (Fe), copper (Cu), zinc (Zn), zirconium(Zr), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). i, j, k, m, and n represent values within ranges of0.8≦i≦1.2, 0<j<0.5, 0≦k≦0.5, j+k<1, −0.1≦m≦0.2, and 0≦n≦0.1. Inaddition, the composition of lithium is different depending on thecharge and discharge state, and the value of i represents a value in acompletely discharged state.)Li_(o)Ni_((1-p))M5_(p)O_((1-q))F_(r)  (Chem. V)

(Here, M5 represents at least one kind selected from a group consistingof cobalt (Co), manganese (Mn), magnesium (Mg), aluminum (Al), boron(B), titanium (Ti), vanadium (V), chrome (Cr), iron (Fe), copper (Cu),zinc (Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). o, p, q, and r represent values within ranges of0.8≦o≦1.2, 0.005≦p≦0.5, −0.1q≦0.2, 0≦r≦0.1. In addition, the compositionof lithium is different depending on a charge and discharge state, andthe value of o represents a value in a completely discharged state.)Li_(s)Co_((1-t))M6_(t)O_((1-u))F_(v)  (Chem. VI)

(Here, M6 represents at least one kind selected from a group consistingof nickel (Ni), manganese (Mn), magnesium (Mg), aluminum (Al), boron(B), titanium (Ti), vanadium (V), chrome (Cr), iron (Fe), copper (Cu),zinc (Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). s, t, u, and v represent values within ranges of0.8≦s≦1.2, 0≦t<0.5, −0.1≦u≦0.2, 0≦v≦0.1. In addition, a composition oflithium is different depending on a charge and discharge state, and avalue of s represents a value in a completely discharged state.)Li_(w)Mn_((1-x))M7_(x)O_(y)F_(z)  (Chem. VII)

(Here, M7 represents at least one kind selected from a group consistingof cobalt (Co), nickel (Ni), magnesium (Mg), aluminum (Al), boron (B),titanium (Ti), vanadium (V), chrome (Cr), iron (Fe), copper (Cu), zinc(Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). w, x, y, and z represent values within ranges of0.9≦w≦1.1, 0≦x≦0.6, 3.7≦y≦4.1, and 0≦g≦0.1. In addition, a compositionof lithium is different depending on a charge and discharge state, and avalue of w represents a value in a completely discharged state.)

Among these, it is preferable to use lithium composite phosphate havingan olivine type structure expressed by Chem. I and Chem. III as thepositive electrode active material. Particularly, as M1 in Chem. I andM3 in Chem. III, iron (Fe) is preferably included. As the content ofiron (Fe) is larger, it is more preferable. This is because when theelectrolyte including both of the non-fluidic electrolyte and thefluidic electrolyte of the present disclosure is used, relativelysuperior battery characteristics may be obtained.

Furthermore, from the viewpoints of obtaining relatively high electrodefilling property and cycle characteristic, a composite particle, inwhich a surface of a core particle formed from any one of theabove-described lithium-containing compounds is coated with a fineparticle formed from any one of other lithium-containing compounds or acarbon material, may be used.

In addition, examples of the positive electrode material capable ofoccluding and emitting lithium ions include oxide, disulfide,chalcogenide, conductive polymer, and the like. Examples of the oxideinclude vanadium oxide (V₂O₅), titanium dioxide (TiO₂), manganesedioxide (MnO₂), and the like. Examples of the disulfide include irondisulfide (FeS₂), titanium disulfide (TiS₂), molybdenum disulfide(MoS₂), and the like. As the chalcogenide, a layered compound or aspinel type compound is particularly preferable, and examples thereofinclude niobium selenide (NbSe₂) and the like. Examples of theconductive polymer include sulfur, polyaniline, polythiophene,polyacetylene, polypyrrole, and the like. The positive electrodematerial may be another material other than the above-describedmaterials. In addition, two or more kinds of the above-describedpositive electrode materials may be mixed in an arbitrary combination.

A specific surface area of the positive electrode active material is setto be 0.05 to 2.0 m²/g in measurement according to a BET (Brunauer,Emmett, Teller) method in a case of using nitrogen (N₂) as an absorptiongas, and preferably 0.2 to 0.7 m²/g. This is because a relativelyeffective charge and discharge characteristic may be obtained withinthis range.

In addition, as the conductive material, for example, a carbon materialsuch as carbon black and graphite is used. As the binding material, forexample, at least one kind selected from resin materials such aspolyvinylidene fluoride (PVdF), polytetrafluoroethylene (PTFE),polyacrylonitrile (PAN), styrene butadiene rubber (SBR), andcarboxymethyl cellulose (CMC), and copolymers containing these resinmaterials as a main component.

Negative Electrode

For example, the negative electrode has a configuration in which anegative electrode active material layer 12B is provided on bothsurfaces of a negative electrode current collector 12A having a pair ofopposite surfaces, respectively. The negative electrode currentcollector 12A is formed from, for example, metallic foil such as copperfoil. As shown in FIG. 4B, each negative electrode tab 12C, which isconnected to the negative electrode lead 3, continuously extends fromthe negative electrode current collector 12A. Plural sheets of thenegative electrode tabs 12C, which extend from a plurality of thenegative electrodes 12 that are laminated, are fixed to each other andthe negative electrode current collector 12A is connected thereto. Inaddition, in FIG. 4B, so as to clarify the configuration of the negativeelectrode tab 12C, the negative electrode active material layer 12B isshown in a state in which a part thereof is not formed. However,actually, the negative electrode active material layer 12B is formed ata portion excepting a portion of the negative electrode tab 12C.

The negative electrode active material layer 12B contains any one ormore kinds of negative electrode materials, which are capable ofoccluding and emitting lithium ions, as a negative electrode activematerial, and may contain other materials such as a binding material anda conductive material similarly to the positive electrode activematerial layer 11B, according to necessity.

In addition, in the battery 1, an electrochemical equivalent of thenegative electrode material capable of occluding and emitting lithiumions is larger than that of the positive electrode 11, and istheoretically set in order for a lithium metal not to precipitate to thenegative electrode 12 during charging.

Examples of the negative electrode material capable of occluding andemitting include carbon materials such as a non-graphitization carbon,easy-graphitization carbon, graphite, pyrolytic carbons, cokes, glassycarbons, a baked body of an organic polymeric material, carbon fiber,and activated charcoal. Among these, examples of the cokes include pitchcoke, needle coke, petroleum coke, and the like. The baked body of anorganic polymeric material represents a carbonized material that isobtained by baking polymeric material such as a phenol resin or a furanresin at an appropriate high temperature, and may be classified intonon-graphitization carbon or easy-graphitization carbon in some parts.These carbon materials are preferable because a change in the crystalstructure, which occurs during charging and discharging, is very small,and a high charging and discharging capacity may be obtained, and asatisfactory cycle characteristic may be obtained. Particularly,graphite is preferable because an electrochemical equivalent may belarge and a high energy density may be obtained. In addition,non-graphitization carbon is preferable because a superior cyclecharacteristic may be obtained. Furthermore, a material of which chargeand discharge electric potential is low, specifically, a material ofwhich charge and discharge electric potential is close to that of alithium metal is preferable because high energy density of the batterymay be easily realized.

As the negative electrode material capable of occluding and emittinglithium ions, a material, which is capable of occluding and emittinglithium ions and contains at least one kind of a metallic element and ametalloid element, may be exemplified. This is because a high energydensity may be obtained when this material is used. Particularly, it ismore preferable to use this material in combination with a carbonmaterial because a high energy density and a superior cyclecharacteristic may be obtained. The negative electrode material may bean elementary metallic element or metalloid element, an alloy thereof,or a compound thereof, and the negative electrode material may at leastpartially have one or more kinds of phases thereof. In addition, in thepresent disclosure, in addition to an alloy of two or more kinds ofmetallic elements, the term “alloy” also includes an alloy containingone or more kinds of metallic elements and one or more kinds ofmetalloid elements. In addition, the alloy may contain a nonmetallicelement. The texture of the alloy includes a solid solution, a eutecticcrystal (a eutectic mixture), an intermetallic compound, and a texturein which two or more kinds of these textures coexist.

Examples of the metal elements or the metalloid elements, which make upthe negative electrode material, include metal elements or metalloidelements that are capable of forming an alloy with lithium.Specifically, examples of the metal elements or the metalloid elementsinclude magnesium (Mg), boron (B), aluminum (Al), titanium (Ti), gallium(Ga), indium (In), silicon (Si), germanium (Ge), tin (Sn), lead (Pb),bismuth (Bi), cadmium (Cd), silver (Ag), zinc (Zn), hafnium (Hf),zirconium (Zr), yttrium (Y), palladium (Pd), platinum (Pt), and thelike. These may be crystalline materials or amorphous materials.

As the negative electrode material, for example, materials containing ametallic element or a metalloid element of group 4B in a short-periodtype periodic table as a constituent element are preferable, materialscontaining at least one of silicon (Si) and tin (Sn) as a constituentelement are more preferable, and materials containing at least siliconis still more preferable. This is because silicon (Si) and tin (Sn) havelarge capacity of occluding and emitting lithium ions and may obtain ahigh energy density. Examples of the negative electrode material, whichcontains at least one kind of silicon and tin, include elementarysilicon, alloys or compounds of silicon, elementary tin, alloys orcompounds of tin, and materials that at least partially have one or morekinds of these.

Examples of the alloys of silicon include alloys containing, as asecondary constituent element other than silicon, at least one kindselected from a group consisting of tin (Sn), nickel (Ni), copper (Cu),iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium (In), silver(Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony (Sb), andchromium (Cr). Examples of the alloys of tin include alloys containing,a secondary constituent element other than tin (Sn), at least one kindselected from a group consisting of silicon (Si), nickel (Ni), copper(Cu), iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium (In),silver (Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony (Sb),and chromium (Cr).

Examples of the compounds of tin (Sn) or silicon (Si) include compoundscontaining oxygen (O) or carbon (C). Furthermore, the tin or siliconcompounds may contain the above-described secondary constituent elementin addition to tin (Sn) or silicon (Sn).

Among these, as the negative electrode material, a SnCoC-containingmaterial, which contains cobalt (Co), tin (Sn), and carbon (C) as aconstituent element, and in which a content of carbon is 9.9 to 29.7mass %, a ratio of cobalt (Co) on the basis of a sum of tin (Sn) andcobalt (Co) is 30 to 70 mass %, is preferable. This is because a highenergy density and a superior cycle characteristic may be obtained inthis compositional range.

This SnCoC-containing material may further contain another constituentelement according to necessity. As another constituent element, forexample, silicon (Si), iron (Fe), nickel (Ni), chrome (Cr), indium (In),niobium (Nb), germanium (Ge), titanium (Ti), molybdenum (Mo), aluminum(Al), phosphorus (P), gallium (Ga), or bismuth (Bi) is preferable, andthe SnCoC-containing material may contain two or more kinds of theseconstituent elements. This is because the capacity or cyclecharacteristic may be further improved.

In addition, the SnCoC-containing material has a phase including tin(Sn), cobalt (Co), and carbon (C), and it is preferable that this phasehave a low crystalline or amorphous structure. In addition, in theSnCoC-containing material, it is preferable that at least part of carbon(C) present as a constituent element be bonded to a metallic element ora metalloid element present as another constituent element. A decreasein cycle characteristic is considered to be due to aggregation orcrystallization of tin (Sn) or the like, but when carbon (C) is bondedto another element, the aggregation or crystallization may besuppressed.

Examples of the measurement method of examining the bonding state of theelement include X-ray photoelectron spectroscopy (XPS). In the XPS, in acase of graphite, a peak of the 1 s orbital (C1s) of carbon is shown at284.5 eV in a device having undergone an energy calibration such that apeak of the 4f orbital (Au4f) of a gold atom is obtained at 84.0 eV. Inaddition, in a case of surface-contaminated carbon, the peak is shown at284.8 eV. On the other hand, in a case where the charge density of thecarbon atom increases, for example, in a case where carbon is bonded tothe metallic element or the metalloid element, the C1s peak is shown ina range below 284.5 eV. That is, in a case where a peak of a syntheticwave of C1s, which is obtained for the SnCoC-containing material, isshown at a range below 284.5 eV, at least part of the carbon containedin the SnCoC-containing material is in a state of being bonded to themetallic element or the metalloid element present as another constituentelement.

In addition, in the XPS measurement, for example, the C1s peak is usedfor calibration of an energy axis of spectrum. Normally,surface-contaminated carbon is present at the surface of theSnCoC-containing material, and thus the C1s peak of thesurface-contaminated carbon is set to 284.8 eV, and this is used as anenergy reference. In the XPS measurement, a waveform of the C1s peak isobtained as a waveform that contains both of the peak of thesurface-contaminated carbon and the peak of the carbon in theSnCoC-containing material. Therefore, the peak of thesurface-contaminated carbon and the peak of the carbon in theSnCoC-containing material are separated from each other, for example, byan analysis conducted using commercially available software. In thewaveform analysis, the position of a main peak present on the minimumbinding energy side is used as an energy reference (284.8 eV).

Furthermore, examples of the negative electrode material, which mayocclude and emit lithium ions, further include other metallic compoundsand polymeric materials. Examples of other metallic compounds includeoxides such as lithium titanate (Li₄Ti₅O₁₂), manganese dioxide (MnO₂),and vanadium oxide (V₂O₅, V₆O₁₃), sulfides such as nickel sulfide (NiS)and molybdenum sulfide (MoS₂), and lithium nitrides such as lithiumnitride (Li₃N). Examples of the polymeric materials includepolyacetylene, polyaniline, polypyrrole, and the like.

Separator

The separator 13 is a component that isolates the positive electrode 11and the negative electrode 12 from each other to preventshort-circuiting due to mutual contact of the electrodes, and allowslithium ions to pass therethrough. The separator 13 is formed from, forexample, a porous membrane of a synthetic resin such aspolytetrafluoroethylene, polypropylene, and polyethylene, or a porousmembrane of a ceramic, and may have a structure in which two or morekinds of the porous membranes are laminated. The separator 13 isimpregnated with the non-fluidic electrolyte.

The separator 13 may contain any one of polypropylene (PP),polyvinylidene fluoride (PVdF), and polytetrafluoroethylene (PTFE) inaddition to polyethylene. In addition, the separator 13 may beconfigured by the ceramic porous membrane and various kinds ofpolyethylene (PE), polypropylene (PP), and polytetrafluoroethylene(PTFE) may be mixed to the ceramic porous membrane. Furthermore,polyvinylidene fluoride (PVdF) may be applied or deposited onto thesurface of a porous membrane of polyethylene (PE), polypropylene (PP),and polytetrafluoroethylene (PTFE). In a case where polyvinylidenefluoride (PVdF) is applied onto the surface of the porous membrane,inorganic particles such as alumina (Al₂O₃) and silica (SiO₂) may bemixed to the polyvinylidene fluoride (PVdF).

In addition, the separator 13 may have a structure in which two or morekinds of porous membranes of polyethylene (PE), polypropylene (PP), andpolytetrafluoroethylene (PTFE) are laminated. A porous membrane ofpolyolefin is preferable from the viewpoints that the short-circuitprevention effect is superior and the stability of a battery due to theshut-down effect is realized.

(2-2) Second Configuration of Battery

A second configuration of the battery of the second embodiment is alaminated film type battery in which instead of the laminated electrodebody, strip-shaped electrodes are laminated and are wound to obtain awound electrode body, and then the wound electrode body is packaged witha laminated film.

FIG. 5 is an exploded perspective view illustrating a secondconfiguration example of the battery 1 according to the secondembodiment of the present disclosure, and FIG. 6 is a view illustratingthe cross-sectional structure of a wound electrode body 20 along a lineVI-VI in FIG. 5. The battery 1 of the second configuration is the sameas the battery 1 of the first configuration except that the electrodebody is made to have a wound structure, and thus the same referencenumerals will be given to common portions.

The wound electrode body 20 is formed by laminating strip-shapedpositive electrode and negative electrode 21 and 22 through a separator13 and a non-fluidic electrolyte layer 15 and by winding the resultantlaminated body, and a winding distal end portion is fixed by a fixingmember 14 according to necessity. The non-fluidic electrolyte layer 15and a fluidic electrolyte (not shown) are present inside the battery 1.

(2-3) Method of Manufacturing Battery

The battery 1 of the second embodiment is manufactured, for example, bythe following three kinds of manufacturing methods (first to thirdmanufacturing methods).

(2-3-1) First Manufacturing Method

In the first manufacturing method, description will be made with respectto the method (1) of impregnating the electrolytic solution into thepolymeric material such as polyvinylidene fluoride at normal temperatureor while being heated, which is described in the first embodiment.

Manufacturing of Positive Electrode

First, a positive electrode 11 is prepared. For example, a positiveelectrode material, a binding material, and a conductive material aremixed to form a positive electrode mixture, and then the positiveelectrode mixture is dispersed in an organic solvent to form paste-likepositive electrode mixture slurry. Subsequently, the positive electrodemixture slurry is uniformly applied to both surfaces of a positiveelectrode current collector 11A by using a doctor blade, a bar coater,or the like, and is dried. Finally, a coated film is compression-moldedby using a roll pressing machine or the like while heating the coatedfilm according to necessity to form a positive electrode active materiallayer 11B. In this case, the compression molding may be repeated pluraltimes.

Manufacturing of Negative Electrode

Next, a negative electrode 12 is prepared. For example, a negativeelectrode material, a binding material, and a conductive materialaccording to necessity are mixed to form a negative electrode mixture,and then the negative electrode mixture is dispersed in an organicsolvent to form paste-like negative electrode mixture slurry.Subsequently, the negative electrode mixture slurry is uniformly appliedto both surfaces of a negative electrode current collector 12A by usinga doctor blade, a bar coater, or the like, and is dried. Finally, acoated film is compression-molded by using a roll pressing machine orthe like while heating the coated film according to necessity to form anegative electrode active material layer 12B.

Preparation of Electrolytic Solution

A solvent and an electrolyte salt are mixed in a predetermined ratio,whereby an electrolytic solution is prepared.

Next, a polymeric material such as polyvinylidene fluoride (PVdF), whichsupports the electrolytic solution and forms a non-fluidic electrolytelayer 15, is deposited onto both surfaces of the positive electrode 11and the negative electrode 12, or both surfaces of a separator 13,respectively. The polymeric material is mixed in a solvent, and isapplied or sprayed onto both surfaces of the positive electrode 11 andthe negative electrode 12, or both surfaces of the separator 13, andthen the solvent is volatilized, whereby the polymeric material isdeposited onto the surfaces. At this time, a deposition amount of thepolymeric material is set such that both of the non-fluidic electrolyteand the fluidic electrolyte are present after forming the battery from arelationship with an amount of electrolytic solution to be injectedlater. In addition, it is preferable to set the deposition amount of thepolymeric material such that the non-fluidic electrolyte and the fluidicelectrolyte have the volume ratio described in the first embodimentafter forming the battery. As the polymeric material, the materialsdescribed in the first embodiment may be used.

Next, the positive electrode 11 and the negative electrode 12 arelaminated through the separator 13, and the fixing member 14 is adheredto the resultant laminated structure so as to fix the laminatedstructure, whereby a laminated electrode body 10 is manufactured.Subsequently, a positive electrode lead 2 is attached to a portion atwhich a plurality of the positive electrode tabs 11C extending from aplurality of the positive electrodes 11 are fixed to each other byultrasonic welding or the like. Similarly, a negative electrode lead 3is attached to a portion at which a plurality of the negative electrodetabs 12C extending from a plurality of the negative electrodes 12 arefixed to each other by ultrasonic welding or the like.

In a case of manufacturing the wound electrode body 20, the positiveelectrode lead 2 is attached to the positive electrode 21, and thenegative electrode lead 3 is attached to the negative electrode 22. Thepositive electrode lead 2 is connected to a portion of the positiveelectrode 21, at which a positive electrode active material layer 21B isnot formed and thus a positive electrode current collector 21A isexposed, by ultrasonic welding or the like. Similarly, with respect tothe negative electrode lead 3, the negative electrode lead 3 isconnected to a portion of the negative electrode 22, at which a negativeelectrode active material layer 22B is not formed and thus a negativeelectrode current collector 22A is exposed, by ultrasonic welding or thelike. Subsequently, the positive electrode 21 and the negative electrode22 are laminated through the separator 13 and are wound, and then thefixing member 14 is adhered to an outermost circumferential portion ofthe resultant wound electrodes, whereby the wound electrode body 20 ismanufactured.

Subsequently, the laminated electrode body 10 or the wound electrodebody 20 is accommodated in the concave portion 5 a that is provided tothe exterior packaging member 5, and then the exterior packaging member5 is thermally fused to form a bag shape. Subsequently, a predeterminedamount of electrolytic solution is injected into the bag-shaped exteriorpackaging member 5, and then an opening of the exterior packaging member5 is sealed by thermal fusion in a decompressed environment. Finally,the exterior packaging member 5 is heated while applying weight theretoto impregnate the electrolytic solution into the polymeric material,whereby the non-fluidic electrolyte layer 15 is formed. As a result, thebattery 1 of the present disclosure may be obtained.

(2-3-2) Second Manufacturing Method

In this second manufacturing method, description will be made withrespect to the method (2) of performing a polymerization treatment suchas ultraviolet curing or thermal curing with respect to the electrolyticsolution containing the polymeric material present as a polymericgelling agent, which is described in the first embodiment.

First, the positive electrode 11 and the negative electrode 12 areprepared, respectively, similarly to the first manufacturing method.Subsequently, a precursor solution, which contains the electrolyticsolution and the polymeric material present as a polymeric gelling agentthat are described in the first embodiment, and a polymerizationinitiator and a polymerization prohibitor according to necessity, isprepared. The precursor solution is applied onto the surface of thepositive electrode 11 and the negative electrode 12, and is cured byirradiation of ultraviolet rays or heating, whereby the non-fluidicelectrolyte layer 15 is formed.

Subsequently, the laminated electrode body 10 is manufactured by thesame method as the first manufacturing method by using the positiveelectrode 11 and the negative electrode 12 on which the non-fluidicelectrolyte layer 15 is formed.

In a case of manufacturing the wound electrode body 20, the positiveelectrode lead 2 and the negative electrode lead 3 are attached to thepositive electrode 21 and the negative electrode 22 on which thenon-fluidic electrolyte layer 15 is formed, respectively, and then thewound electrode body 20 is manufactured by the same method as the firstmanufacturing method.

Finally, the laminated electrode body 10 or the wound electrode body 20is accommodated in the concave portion 5 a that is provided to theexterior packaging member 5, and then the exterior packaging member 5 isthermally fused to form a bag shape. Subsequently, a predeterminedamount of electrolytic solution is injected into the bag-shaped exteriorpackaging member 5, and then an opening of the exterior packaging member5 is sealed by thermal fusion, for example, in a decompressedenvironment, whereby the battery 1 of the present disclosure may beobtained. Therefore, both of the non-fluidic electrolyte layer 15 andthe fluidic electrolyte are present inside the battery 1. At this time,it is preferable to set an addition amount of the electrolytic solutionsuch that the non-fluidic electrolyte layer 15 that is formed in advanceand the fluidic electrolyte have the volume ratio described in the firstembodiment.

(2-3-3) Third Manufacturing Method

In this third manufacturing method, description will be made withrespect to the method (3) in which a material obtained by dissolving thepolymeric material in the electrolytic solution at a high temperature iscooled to normal temperature, which is described in the firstembodiment.

First, the positive electrode 11 and the negative electrode 12 areprepared, respectively, similarly to the first manufacturing method.Subsequently, the electrolytic solution, the polymeric material, and thesolvent that are described in the first embodiment are dissolved at ahigh-temperature to prepare a precursor solution, and this precursorsolution is applied onto a surface of the positive electrode 11 and thenegative electrode 12 and this applied precursor solution is cooled tonormal temperature, whereby the non-fluidic electrolyte layer 15 isformed.

Subsequently, the laminated electrode body 10 is manufactured by thesame method as the first manufacturing method by using the positiveelectrode 11 and the negative electrode 12 on which the non-fluidicelectrolyte layer 15 is formed. In a case of manufacturing the woundelectrode body 20, the positive electrode lead 2 and the negativeelectrode lead 3 are attached to the positive electrode 21 and thenegative electrode 22 on which the non-fluidic electrolyte layer 15 isformed, respectively, and then the wound electrode body 20 ismanufactured by the same method as the first manufacturing method.

Finally, the laminated electrode body 10 or the wound electrode body 20is accommodated in the concave portion 5 a that is provided to theexterior packaging member 5, and then the exterior packaging member 5 isthermally fused to form a bag shape. Subsequently, a predeterminedamount of electrolytic solution is injected into the bag-shaped exteriorpackaging member 5, and then an opening of the exterior packaging member5 is sealed by thermal fusion, for example, in a decompressedenvironment, whereby the battery 1 of the present disclosure may beobtained. Therefore, both of the non-fluidic electrolyte layer 15 andthe fluidic electrolyte are present inside the battery 1. At this time,it is preferable to set an addition amount of the electrolytic solutionsuch that the non-fluidic electrolyte layer 15 that is formed in advanceand the fluidic electrolyte have the volume ratio described in the firstembodiment.

Effect

In the battery of the second embodiment, superior batterycharacteristics may be maintained even in a high-temperature environmentor a low-temperature environment.

3. Third Embodiment

In this third embodiment, description will be made with respect toanother configuration example of the battery using the electrolyte ofthe first embodiment.

(3-1) First Configuration of Battery

A first configuration of the battery of the third embodiment is aso-called square battery in which a laminated electrode body obtained bylaminating electrodes is inserted to a square exterior casing. FIG. 7shows a configuration of a square battery 30 according to the thirdembodiment of the present disclosure. A laminated electrode body 40 isaccommodated in a square exterior casing 31. In addition, the squarebattery 30 may be assembled by using a wound electrode body instead ofthe laminated electrode body 40.

The square battery 30 includes the square tubular exterior casing 31,the laminated electrode body 40 present as a generator element that isaccommodated in the exterior casing 31, a battery lid 32 that closes anopening of the exterior casing 31, an electrode pin 33 that is providedat an approximately central portion of the battery lid 32, and the like.

The exterior casing 31 is formed as a hollow square tubular body havinga bottom, for example, with a metal such as iron (Fe) havingconductivity. It is preferable that the inner surface of the exteriorcasing 31 have a configuration in which, for example, nickel plating isperformed, or a conductive coating material is applied to increase theconductivity of the exterior casing 31. In addition, an outercircumferential surface of the exterior casing 31 may be covered with anexterior label formed from, for example, a plastic sheet, paper, or thelike, or an insulating coating material may be applied thereto so as toprotect the exterior casing 31. Similarly to the exterior casing 31, thebattery lid 32 may be formed from, for example, a metal such as iron(Fe) having conductivity.

The laminated electrode body 40 has the same configuration as the secondembodiment, and may be obtained by laminating a positive electrode and anegative electrode through a separator. Both a non-fluidic electrolyteand a fluidic electrolyte are present between the positive electrode andthe separator of the laminated electrode body 40 and between thenegative electrode and the separator of the laminated electrode body 40.The positive electrode, the negative electrode, and the separator arethe same as those in the first embodiment and the second embodiment, andthus a detailed description thereof will not be repeated.

A positive electrode terminal 41 that is connected a plurality of thepositive electrodes and a negative terminal that is connected to aplurality of the negative electrode current collectors are provided tothe laminated electrode body 40 having the above-describedconfiguration. The positive electrode terminal 41 and the negativeelectrode terminal lead out to one end of the laminated electrode body40 in an axial direction. In addition, the positive electrode terminal41 is connected to a lower end of the electrode pin 33 with fixing meanssuch as welding. In addition, the negative electrode terminal isconnected to the inner surface of the exterior casing 31 with fixingmeans such as welding.

The electrode pin 33 is formed from a conductive axis member, and issupported by an insulating body 34 in a state in which a head portionprotrudes from an upper end of the insulating body 34. The electrode pin33 is fixed to an approximately central portion of the battery lid 32through the insulating body 34. The insulating body 34 is formed from ahighly insulating material, and is fitted into a penetration hole 35provided on a surface side of the battery lid 32. In addition, theelectrode pin 33 penetrates through the penetration hole 35, and aleading end of the positive electrode terminal 41 is fixed to the lowerend surface of the electrode pin 33.

The battery lid 32, to which the electrode pin 33 and the like areprovided, is fitted into the opening of the exterior casing 31, andcontact surfaces of the exterior casing 31 and the battery lid 32 areadhered to each other with fixing means such as welding. Therefore, theopening of the exterior casing 31 is sealed by the battery lid 32, andthus is configured in an air-tight and fluid-tight manner. An innerpressure release mechanism 36, which ruptures a part of the battery lid32 when a pressure inside the exterior casing 31 increases by apredetermined value or more, and allows the inner pressure to be escaped(emitted) to the outside, is provided to the battery lid 32.

The inner pressure release mechanism 36 includes two first openinggrooves 36 a (one of the first opening grooves 36 a is not shown) thatlinearly extend in a longitudinal direction in the inner surface of thebattery lid 32, and a second opening groove 36 b that extends in alateral direction orthogonal to the longitudinal direction in the sameinner surface of the battery lid 32 and both ends thereof communicatewith the two first opening grooves 36 a. The two first opening grooves36 a are provided to be parallel with each other so as to followlong-side side outer edge of the battery lid 32 in the vicinity of innerside of two long-side sides that are positioned to be opposite to eachother in the lateral direction of the battery lid 32. In addition, thesecond opening groove 36 b is provided to be positioned at approximatelythe central portion between one short-side side outer edge and theelectrode pin 33 at one side of the longitudinal direction of theelectrode pin 33.

For example, the first opening grooves 36 a and the second openinggroove 36 b have a V-shape with a cross-section opened at a lowersurface side. In addition, the shape of the first opening groove 36 aand the second opening groove 36 b is not limited to the V-shapeillustrated in this embodiment. For example, the shape of the firstopening grooves 36 a and the second opening groove 36 b may be a U-shapeor a semi-circular shape.

An electrolytic solution injection port 37 is provided to penetratethrough the battery lid 32. The electrolytic solution injection port 37is used to inject an electrolytic solution after covering the exteriorcasing 31 with the battery lid 32, and is sealed with a sealing member38 after injection of the electrolytic solution.

(3-2) Method of Manufacturing Battery

The laminated electrode body 40 of the third embodiment is manufacturedin accordance with the first manufacturing method, the secondmanufacturing method, or the third manufacturing method that isdescribed in the second embodiment.

In addition, in a case where the thickness of the square battery 30 islarge, it is preferable to manufacture the square battery 30 inaccordance with the second manufacturing method or the thirdmanufacturing method that is described in the second embodiment.Differently from the laminated film type battery 1 in the secondembodiment, in the square battery 30 having a large thickness, it isdifficult to form the non-fluidic electrolyte layer by compression andheating from the outside of the battery after the sealing so as to causethe electrolytic solution is supported by the polymeric material.Therefore, it is necessary to manufacture the laminated electrode body40 after forming the non-fluidic electrolyte layer on the surfaces ofthe positive electrode and the negative electrode in advance and toassemble the square battery 30.

Assembling of Square Battery

The laminated electrode body 40, which is manufactured by forming thenon-fluidic electrolyte layer on the surfaces of the positive electrodeand the negative electrode in advance, is accommodated inside theexterior casing 31 that is a square casing formed from, for example, ametal such as aluminum (Al) and iron (Fe).

In addition, after connecting the electrode pin 33 provided to thebattery lid 32 and the positive electrode terminal 41 connected to thelaminated electrode body 40, the entrance of the exterior casing 31 issealed with the battery lid 32. Then, the electrolytic solution isinjected from the electrolytic solution injection port 37, for example,in a decompressed pressure. Therefore, both of the non-fluidicelectrolyte and the fluidic electrolyte are present in the battery. Atthis time, it is preferable to set an addition amount of theelectrolytic solution such that the non-fluidic electrolyte layer thatis formed in advance and a fluidic electrolyte layer have the volumeratio described in the first embodiment. Finally, the electrolyticsolution injection port 37 is sealed with the sealing member 38. In thismanner, the square battery 30, which is shown in FIG. 7, of the presentdisclosure may be obtained.

Effect

The square battery 30 of the third embodiment has the same effect as thebattery 1 of the second embodiment.

4. Fourth Embodiment

In a fourth embodiment, description will be made with respect to anotherconfiguration example of the battery using the electrolyte of the firstembodiment.

(4-1) Configuration of Battery

Structure of Battery

FIG. 8 shows a cross-sectional view illustrating an example of acylindrical battery 50 according to the fourth embodiment. For example,the cylindrical battery 50 is a nonaqueous electrolyte secondary batterythat is capable of being charged and discharged. The cylindrical battery50 is a so-called cylinder type and includes a wound electrode body 60formed by winding strip-shaped positive and negative electrodes 61 and62 with a separator 63 interposed therebetween in a battery casing 51having an approximately hollow column shape. In the wound electrode body60, both of the non-fluidic electrolyte and the fluidic electrolyte (notshown) are present between the positive electrode 61 and the separator63 and between the negative electrode 62 and the separator 63,respectively.

The battery casing 51 is formed from, for example, iron on whichnickel-plating is performed, and one end of the battery casing 51 isclosed, and the other end is opened. At the inside of the battery casing51, a pair of insulating plates 52 a and 52 b is disposed to beorthogonal to a winding circumferential surface such that the woundelectrode body 60 is interposed between the insulating plates 52 a and52 b.

As a material of the battery casing 51, iron (Fe), Nickel (Ni),stainless steel (SUS), aluminum (Al), titanium (Ti), or the like may beexemplified. For preventing the battery casing 51 from being corrodeddue to an electrochemical electrolytic solution along with a chargingand discharging of the cylindrical battery 50, for example, nickel orthe like may be plated on the battery casing 51. At the opened end ofthe battery casing 51, a battery lid 53 that is a positive electrodelead plate, a safety valve mechanism and a PTC (Positive TemperatureCoefficient) element 57 provided at an inner side of the battery lid 53are mounted in such a manner that they are caulked through an insulatingsealing gasket 58.

The battery lid 53 is formed from, for example, the same material asthat of the battery casing 51, and has an opening through which a gasgenerated inside the battery is discharged. In the safety valvemechanism, a safety valve 54, a disc holder 55, and a shielding disc 56overlap each other in this order. A protruding portion 54 a of thesafety valve 54 is connected to a positive electrode lead 65 protrudedfrom the wound electrode body 60 through a sub-disc 59 disposed to covera hole portion 56 a formed at the central portion of the shielding disc56. When the safety valve 54 and the positive electrode lead 65 areconnected to each other through the sub-disc 59, it is possible toprevent the positive electrode lead 65 from being drawn from the holeportion 56 a at the time of reversion of the safety valve 54. Inaddition, the safety valve mechanism is electrically connected to thebattery lid 53 through the PTC element 57.

In the safety valve mechanism, when an inner pressure of the cylindricalbattery 50 reaches a predetermined value or more due to a battery innershort-circuit or heating from the outside of the battery, the safetyvalve 54 is reversed, and thus the protruding portion 54 a, the batterylid 53, and the wound electrode body 60 are electrically disconnected.That is, when the safety valve 54 is reversed, the positive electrodelead 65 is pressed by the shielding disc 56, and thus the connectionbetween the safety valve 54 and the positive electrode lead 65 isreleased. The disc holder 55 is formed of an insulating material, andwhen the safety valve 54 is reversed, the safety valve 54 and theshielding disc 56 are insulated.

In addition, in a case where a gas is further generated inside thebattery and thus the battery inner pressure is further increased, a partof the safety valve 54 is broken up and the gas is discharged to thebattery lid 53 side.

In addition, for example, a plurality of gas discharge holes (not shown)are provided at the periphery of the hole portion 56 a of the shieldingdisc 56, and thus in a case where a gas is generated from the woundelectrode body 60, the gas is effectively discharged to the battery lid53 side.

When the temperature is raised, the resistance value of the PTC element57 increases, and thus the battery lid 53 and the wound electrode body60 are electrically disconnected. Therefore, a current is blocked andthus abnormal heat generation due to an excessive current is prevented.The gasket 58 is formed from, for example, an insulating material andasphalt is applied on a surface of the gasket 58.

The wound electrode body 60 accommodated in the cylindrical battery 50is wound about a center pin 64. The wound electrode body 60 has the sameconfiguration as the second embodiment, and may be obtained bylaminating the positive electrode 61 and the negative electrode 62 withthe separator 63 interposed therebetween in this order and winding theresultant laminated body in a longitudinal direction. Both of thenon-fluidic electrolyte and the fluidic electrolyte are present betweenthe positive electrode 61 and the separator 63 and between the negativeelectrode 62 and the separator 63 of the wound electrode body 60,respectively. The positive electrode 61, the negative electrode 62, andthe separator 63 are the same as those in the first embodiment or thesecond embodiment, and thus detailed description thereof will not berepeated.

The positive electrode lead 65 is connected to the positive electrode61, and a negative electrode lead 66 is connected to the negativeelectrode 62. The positive electrode lead 65 is welded to the safetyvalve 54 as described above and is electrically connected to the batterylid 53. The negative electrode lead 66 is welded to the battery casing51 and is electrically connected thereto.

(3-2) Method of Manufacturing Battery

Formation of Non-Fluidic Electrolyte Layer

The wound electrode body 60 is manufactured in accordance with thesecond manufacturing method or the third manufacturing method that isdescribed in the second embodiment. Differently from the laminated filmtype battery 1 in the second embodiment, in the cylindrical battery 50,it is difficult to form the non-fluidic electrolyte layer by compressionand heating from the outside of the battery after the sealing.Therefore, it is necessary to manufacture the wound electrode body 60after forming the non-fluidic electrolyte layer on the surfaces of thepositive electrode 61 and the negative electrode 62 in advance and toassemble the cylindrical battery 50.

Assembling of Battery

The positive electrode lead 65 is attached to the positive electrode 61by welding or the like, and the negative electrode lead 66 is attachedto the negative electrode 62 by welding or the like. Then, the positiveelectrode 61 and the negative electrode 62 are wound with the separator63 interposed therebetween to form the wound electrode body 60.

Subsequently, the front end of the positive electrode lead 65 is weldedto the safety valve mechanism, and the leading end of the negativeelectrode lead 66 is welded to the battery casing 51. Then, the woundelectrode body 60 is accommodated in the battery casing 51 with awinding surface of the wound electrode body 60 interposed between thepair of insulating plates 52 a and 52 b. After accommodating the woundelectrode body 60 in the battery casing 51, an electrolytic solution isinjected to the inside of the battery basing 51. Therefore, both of thenon-fluidic electrolyte and the fluidic electrolyte are present insidethe battery. At this time, it is preferable to set the addition amountof the electrolytic solution such that the non-fluidic electrolyte layerthat is formed in advance and the fluidic electrolyte have the volumeratio described in the first embodiment.

Subsequently, the battery lid 53, the safety valve mechanism includingthe safety valve 54 or the like, and the PTC element 57 are fixed to theopened end of the battery casing 51 in such a manner that they arecaulked through the gasket 58. In this manner, the cylindrical battery50, which is shown in FIG. 8, of the present disclosure may be obtained.

Effect

The cylindrical battery 50 of the fourth embodiment has the same effectas the battery 1 of the second embodiment and the square battery 30 ofthe third embodiment.

5. Fifth Embodiment

In a fifth embodiment, description will be made with respect to abattery pack provided with the battery using the electrolyte, in whichboth of the non-fluidic electrolyte and the fluidic electrolyte arepresent, according to the first embodiment.

FIG. 9 shows a block diagram illustrating a circuit configurationexample in a case where the battery (the battery 1, the square battery30, or the cylindrical battery 50) of the present disclosure is appliedto a battery pack. The battery pack includes an assembled battery 301,an exterior package, a switch unit 304 provided with a charge controlswitch 302 a and a discharge control switch 303 a, a current detectingresistor 307, a temperature detecting element 308, and a control unit310.

In addition, the battery pack is provided with a positive electrodeterminal 321 and a negative electrode terminal 322, and at the time ofcharging the battery back, the positive electrode terminal 321 and thenegative electrode terminal 322 are connected to a positive electrodeterminal and a negative electrode terminal of a charger, respectively,to carry out the charge. In addition, at the time of being used for anelectronic apparatus, the positive electrode terminal 321 and thenegative electrode terminal 322 are connected to the positive electrodeterminal and the negative electrode terminal of the electronic apparatusto carry out the discharge.

The assembled battery 301 is obtained by connecting a plurality ofbatteries 301 a in series and/or in parallel. The batteries 301 a arebatteries of the present disclosure. In addition, in FIG. 9, a casewhere six batteries 301 a are connected in two-parallel and three-series(2P3S) is illustrated as an example, but in addition to this, anarbitrary connection method such as n-parallel m-series (n and m areintegers) is possible.

The switch unit 304 is provided with charge control switch 302 a anddiode 302 b and discharge control switch 303 a and diode 303 b, and iscontrolled by the control unit 310. The diode 302 b has a reversedirectional polarity with respect to a charge current that flows in adirection from the positive electrode terminal 321 to the assembledbattery 301, and a forward directional polarity with respect to adischarge current that flows in a direction from the negative electrodeterminal 322 to the assembled battery 301. The diode 303 b has a forwarddirectional polarity with respect to the charge current and a reversedirectional polarity with respect to the discharge current. In addition,in this example, the switch unit 304 is provided at a positive side, butmay be provided at a negative side.

The charge control switch 302 a is controlled by a charge and dischargecontrol unit in such a manner that when a battery voltage becomes anovercharge detection voltage, the charge control switch 302 a is turnedoff, and thus a charge current does not flow through a current path tothe assembled battery 301. After the charge control switch is turnedoff, only discharge through the diode 302 b is possible. In addition,the charge control switch 302 a is controlled by the control unit 310 insuch a manner that when a large current flows during charging, thecharge control switch 302 a is turned off so as to block a chargecurrent flowing through the current path of the assembled battery 301.

The discharge control switch 303 a is controlled by the control unit 310in such a manner that when the battery voltage becomes an overdischargedetection voltage, the discharge control switch 303 a is turned off, andthus a discharge current does not flow through the current path to theassembled battery 301. After the discharge control switch 303 a isturned off, only charging through the diode 303 b is possible. Inaddition, the discharge control switch 303 a is controlled by thecontrol unit 310 in such a manner that when a large current flows duringdischarge, the discharge control switch 303 a is turned off so as toblock a discharge current flowing through the current path of theassembled battery 301.

For example, the temperature detecting element 308 is a thermistor, andis provided in the vicinity of the assembled battery 301 to measure atemperature of the assembled battery 301 and to supply the measuredtemperature to the control unit 310. A voltage detecting unit 311measures the voltage of the assembled battery 301 and the respectivebatteries 301 a making up the assembled battery 301, A/D converts themeasured voltage, and supplies the converted voltage to the control unit310. A current measuring unit 313 measures a current using the currentdetecting resistor 307, and supplies this measured current to thecontrol unit 310.

A switch control unit 314 controls the charge control switch 302 a andthe discharge control switch 303 a of the switch unit 304 on the basisof the voltage and current that are input from the voltage detectingunit 311 and the current measuring unit 313. When the voltage of severalbatteries 301 a becomes the overcharge detection voltage or theoverdischarge detection voltage or less, or when the large currentsuddenly flows, the switch control unit 314 transmits a control signalto the switch unit 304 so as to prevent overcharging, overdischarging,and overcurrent charging and discharging.

Here, for example, in a case where the battery is a lithium ionsecondary battery, and a material, which becomes a lithium alloy in thevicinity of 0 V with respect to Li/Li⁺, is used as the negativeelectrode active material, the overcharge detection voltage is definedto, for example, 4.20 V±0.05V, and the overdischarge detection voltageis defined to, for example, 2.4 V±0.1 V.

As charge and discharge switches, for example, a semiconductor switchsuch as an MOSFET may be used. In this case, parasitic diodes of theMOSFET function as the diodes 302 b and 303 b. In a case where P-channeltype FETs are used as the charge and discharge switches, the switchcontrol unit 314 supplies control signals DO and CO with respect torespective gates of the charge control switch 302 a and the dischargecontrol switch 303 a, respectively. In a case where charge controlswitch 302 a and the discharge control switch 303 a are P-channel typeswitches, the switches are turned on with respect to a gate potentiallower than a source potential by a predetermined value or more. That is,in normal charging and discharging operations, the control signal CO andDO are set to be a low level, and the charge control switch 302 a andthe discharge control switch 303 a are turned on.

In addition, for example, during overcharge or overdischarge, thecontrol signals CO and DO are set to be a high level, and the chargecontrol switch 302 a and the discharge control switch 303 a are turnedoff.

A memory 317 is composed of a RAM or ROM, for example, an EPROM(Erasable Programmable Read Only Memory) that is a nonvolatile memory orthe like. In the memory 317, a value calculated by the control unit 310,an internal resistance value, which is measured at a manufacturingprocess stage, of the battery at an initial state of the respectivebatteries 301 a, and the like are stored in advance, and these value maybe appropriately rewritten. In addition, when a full charge capacity ofthe batteries 301 a is stored in the memory 317, for example, aremaining capacity may be calculated in combination with the controlunit 310.

In a temperature detecting unit 318, the temperature is measured usingthe temperature detecting element 308, and at the time of abnormal heatgeneration, a charge and discharge control is performed, or correctionis performed during calculation of the remaining capacity.

6. Sixth Embodiment

In a sixth embodiment, description will be made with respect toapparatuses such as an electronic apparatus, an electrically drivenvehicle, and an electrical storage device on which each of the batteriesaccording to the second to fourth embodiments or the battery packaccording to the fifth embodiment is mounted. The batteries and thebattery pack described in the second to fifth embodiment may be used tosupply electric power to the apparatuses such as the electronicapparatus, the electrically driven vehicle, and the electrical storagedevice.

Examples of the electronic apparatus include a notebook computer, a PDA(portable information terminal), a cellular phone, a cordless phonehandset, a video movie, a digital still camera, an electronic book, anelectronic dictionary, a music player, a radio, a headphone, a gamingmachine, a navigation system, a memory card, a pacemaker, a hearing aid,an electric tool, an electric shaver, a refrigerator, anair-conditioner, a television, a stereo, a water heater, a microwaveoven, a dishwasher, a washing machine, a dryer, an illuminationapparatus, a toy, a medical apparatus, a robot, a road conditioner, asignal apparatus, and the like.

In addition, examples of the electrically driven vehicle include arailway vehicle, a golf cart, an electrically driven cart, an electricvehicle (including a hybrid car), and the like, and the batteries areused as a driving power supply or an auxiliary power supply of thevehicles.

Examples of the electrical storage device include power supplies forelectrical storage of buildings starting from a house or a powergenerating facility.

Hereinafter, among the above-described application examples, specificexamples of the electrical storage system using an electrical storagedevice to which the batteries of the present disclosure are applied willbe described.

As the electrical storage system, the following configuration may beexemplified. A first electrical storage system is an electrical storagesystem in which an electrical storage device is charged by a powergenerator that performs power generation from renewable energy. A secondelectrical storage system is an electrical storage system that isprovided with an electrical storage device and supplies electric powerto an electronic apparatus that is connected to the electrical storagedevice. A third electrical storage system is an electronic apparatus towhich electric power is supplied from an electrical storage device. Thiselectrical storage system is executed as a system that realizeseffective power supply in cooperation with an external power supplynetwork.

In addition, a fourth electrical storage system is an electricallydriven vehicle provided with a conversion device to which electric poweris supplied from an electrical storage device and which converts theelectric power to a driving force of a vehicle, and a control devicethat performs information processing relating to a vehicle control onthe basis of information relating to the electrical storage device. Afifth electrical storage system is a power system that is provided withan electric power information transmitting and receiving unit thattransmits and receives electric power information to and from otherapparatuses through a network, a charge and discharge control of theabove-described electrical storage device is performed on the basis ofthe information that is received by the transmitting and receiving unit.A sixth electrical storage system is a power system to which electricpower is supplied from the above-described electrical storage device orwhich supplies electric power from a power generator or a power networkto the electrical storage device. Hereinafter, the electrical storagesystem will be described.

(6-1) Electrical Storage System in House as Application Example

An example in which an electrical storage device using the battery ofthe present disclosure is applied to an electrical storage system for ahouse will be described with reference to FIG. 10. For example, in anelectrical storage system 100 for a house 101, electric power issupplied to an electrical storage device 103 from a centralized powersystem 102 such as a thermal power generation 102 a, a nuclear powergeneration 102 b, a hydraulic generation 102 c through a power network109, an information network 112, a smart meter 107, a power hub 108, andthe like. In addition, electric power from an independent power supplysuch as an in-house power generator 104 is supplied to the electricalstorage device 103. The electric power supplied to the electricalstorage device 103 is stored. Electric power that is used in the house101 is supplied by using the electrical storage device 103. The sameelectrical storage system may also be used with respect to a buildingwithout being limited to the house 101.

The in-house power generator 104, power-consuming devices 105, theelectrical storage device 103, a control device 110 that controlsvarious devices, the smart meter 107, and sensors 111 that acquirevarious pieces of information are provided to the house 101. Therespective devices are connected by the power network 109 and theinformation network 112. As the in-house power generator 104, a solarcell, a fuel cell, or the like is used, and generated power is suppliedto the power-consuming devices 105 and/or the electrical storage device103. Examples of the power-consuming devices 105 include a refrigerator105 a, an air-conditioner 105 b, a television receiver 105 c, a bath 105d, and the like. In addition, examples of the power-consuming device 105include an electrically driven vehicle 106. Examples of the electricallydriven vehicle 106 include an electric vehicle 106 a, a hybrid car 106b, and an electric bike 106 c.

The battery of the present disclosure is applied with respect to thiselectrical storage device 103. The battery of the present disclosure maybe configured by the above-described lithium ion secondary battery. Thesmart meter 107 has a function of measuring the amount of commercialpower used and of transmitting this measured used amount to a powercompany. The power network 109 may be any one of a DC power supply type,an AC power supply type, and non-contact power supply type, or acombination thereof.

Examples of the various sensors 111 include a motion sensing sensor, aluminance sensor, an object sensing sensor, a power-consumption sensor,a vibration sensor, a contact sensor, a temperature sensor, an infraredsensor, and the like. Information acquired by the various sensors 111 istransmitted to the control device 110. Weather conditions, conditions ofhuman, or the like is grasped by the information transmitted from thesensors 111, and the power-consuming devices 105 are automaticallycontrolled. Therefore, it is possible to make the power-consumptionminimal. In addition, the control device 110 may transmit informationrelated to the house 101 to an external power company or the likethrough the Internet.

Processes such as divergence of power lines and DC-AC conversion areperformed by the power hub 108. As a communication method of theinformation network 112 connected to the control device 110, a methodusing a communication interface such as a UART (Universal AsynchronousReceiver-Transmitter: transmission and reception circuit forasynchronous serial communication), and a method using a sensor networkcompliant to a wireless communication standard such as Bluetooth (aregistered trademark of Bluetooth SIG), ZigBee, and Wi-Fi may beexemplified. The Bluetooth method is applied to multimedia communicationand may perform one-to-multi-connection communication. The ZigBee uses aphysical layer of IEEE (Institute of Electrical and ElectronicsEngineers) 802.15.4. IEEE 802.15.4 is the name of a short-range wirelessnetwork standard called a PAN (Personal Area Network) or W (Wireless)PAN.

The control device 110 is connected to an external server 113. Theserver 113 may be controlled by any one of the house 101, the powercompany, and a service provider. As information that is transmitted toand received from the server 113, for example, power-consumptioninformation, life pattern information, power rates, weather information,disaster information, and information related to power transaction maybe exemplified. These kinds of information may be transmitted to andreceived from in-house power-consuming devices (for example, televisionreceivers), but may be transmitted to and received from devices (forexample, cellular phones, or the like) positioned at the outside of thehouse. These kinds of information may be displayed on, for example, atelevision receiver, a cellular phone, a PDA (Personal DigitalAssistant), or the like, which has a display function.

The control device 110 that controls each unit includes a CPU (CentralProcessing Unit), a RAM (Random Access Memory), a ROM (Read OnlyMemory), or the like, and is accommodated in the electrical storagedevice 103 in this example. The control device 110 is connected to theelectrical storage device 103, the in-house power generator 104, thepower-consuming devices 105, the various sensors 111, and the server 113through the information network 112, and has, for example, a function ofadjusting the used amount of commercial power and an amount of powergeneration. Furthermore, in addition to this function, the controldevice 110 may have a function of performing power transaction in apower market, or the like.

As described above, a generated output of the in-house power generator104 (photovoltaic generation and wind power generation) as well as thecentralized power system 102 such as the thermal power generation 102 a,the nuclear power generation 102 b, and the hydraulic power generation102 c may be stored in the electrical storage device 103. Therefore,even when the generated output of the in-house power generator 104varies, it is possible to make an amount of power that is transmitted tothe outside uniform, or it is possible to control discharge as much asnecessary. For example, a method of use described below may beconsidered. Specifically, the electric power that is obtained from thephotovoltaic generation is stored in the electrical storage device 103,and inexpensive midnight power is also stored in the electrical storagedevice 103 at night, and then the electric power that is stored in theelectrical storage device 103 is discharged to be used in a period oftime at which a rate is expensive in the day time.

In addition, in this example, an example in which the control device 110is accommodated in the electrical storage device 103 was described, butthe control device 110 may be accommodated in the smart meter 107, ormay be configured independently. Furthermore, the electrical storagesystem 100 may be used in a plurality of homes as targets in regard toan apartment house, or may be used in a plurality of detached houses astargets.

(6-2) Electrical Storage System in Vehicle as Application Example

An example in which the present disclosure is applied to an electricalstorage system for a vehicle will be described with reference to FIG.11. FIG. 11 schematically illustrates a configuration example of ahybrid car that adopts a series hybrid system to which the presentdisclosure is applied. The series hybrid system is a vehicle thattravels with a power-driving force converting device by using electricpower generated by a generator moved by an engine or the electric powerthat is temporarily stored in a battery.

In the hybrid vehicle 200, an engine 201, a generator 202, apower-driving force converting device 203, a driving wheel 204 a, adriving wheel 204 b, a wheel 205 a, a wheel 205 b, a battery 208, avehicle control device 209, various sensors 210, and a charging inlet211 are mounted. As the battery 208, the above-described battery of thepresent disclosure is applied.

The hybrid vehicle 200 travels using the power-driving force convertingdevice 203 as a power source. An example of the power-driving forceconverting device 203 is a motor. The power-driving force convertingdevice 203 operates by electric power of the battery 208, and the torqueof the power-driving force converting device 203 is transferred to thedriving wheels 204 a and 204 b. In addition, the power-driving forceconverting device 203 may be applicable to an AC motor or a DC motor byusing a DC-AC conversion or an invert conversion (AC-DC conversion) asnecessary. The various sensors 210 control the engine speed or theopening degree of a throttle valve (not shown) (throttle opening degree)through the vehicle control device 209. Examples of the various sensors210 include a speed sensor, an acceleration sensor, an engine speedsensor, and the like.

A torque of the engine 201 may be transferred to the generator 202, andelectric power generated by the generator 202 using the torque may bestored in the battery 208.

When the hybrid vehicle 200 is decelerated by a brake mechanism (notshown), a resistance force during the deceleration is added to thepower-driving force converting device 203 as a torque, and regeneratedelectric power that is generated by the power-driving force convertingdevice 203 due to the torque is stored in the battery 208.

When the battery 208 is connected to an external power supply outsidethe hybrid vehicle 200, electric power may be supplied to the battery208 from the external power supply by using the charging inlet 211 as aninput inlet and may store the supplied electric power.

Although not shown, an information processing device that performs aninformation processing related to vehicle control on the basis ofinformation related to the battery may be provided. As this informationprocessing device, for example, an information processing device thatperforms a display of a residual amount of the battery on the basis ofinformation about the residual amount of the battery, or the like may beexemplified.

In addition, hereinbefore, description was made with respect to theseries hybrid car that travels with a motor by using electric powergenerated by a generator moved by an engine or the electric power thatis temporarily stored in a battery as an example. However, the presentdisclosure may be effectively applied to a parallel hybrid car that usesboth the output of the engine and the output of the motor as drivingsources, and utilizes three types of traveling using the engine only,traveling using the motor only, and traveling using the engine and motorby appropriately changing these types. In addition, the presentdisclosure may be effectively applied with respect to a so-calledelectrically driven vehicle that travels using driving by a drivingmotor only without using the engine.

EXAMPLES

Hereinafter, the present disclosure will be described in detail withreference examples. In addition, a configuration of the presentdisclosure is not limited to the examples to be described below.

In addition, imide salt compounds that are used in examples andcomparative examples are as follows.

Chem. A: Lithium bis(fluorosulfonyl) imide

Chem. B: Lithium (fluorosulfonyl)(trifluorosulfonyl) imide

Chem. C: Lithium bis(trifluoromethyl sulfonyl) imide

Examples 1-1 to 1-24, and Comparative Examples 1-1 and 1-2

In examples 1-1 to 1-24, and comparative examples 1-1 and 1-2, a volumeratio of the non-fluidic electrolyte with respect to the entirety of theelectrolyte was changed by changing the film thickness of thenon-fluidic electrolyte layer, and the treatment temperature duringformation of the non-fluidic electrolyte layer was changed, and thenbattery characteristics were evaluated.

Example 1-1 Manufacturing of Positive Electrode

92 parts by mass of lithium iron phosphate (LiFePO₄) present as apositive electrode active material, 3 parts by mass of ketjen blackpresent as a conductive material, and 5 parts by mass of polyvinylidenefluoride (PVdF) present as a binding material were mixed to prepare apositive electrode mixture. Then, this positive electrode mixture wasdispersed in N-methyl-2-pyrrolidone (NMP) to prepare positive electrodemixture slurry. This positive electrode mixture slurry was applied toboth surfaces of a positive electrode current collector formed fromstrip-shaped aluminum foil having a thickness of 10 μm in such a mannerthat part of the positive electrode current collector was exposed. Then,a dispersion medium of the applied positive electrode mixture slurry wasevaporated and dried, and then compression molding was performed using aroll press. In this manner, a positive electrode active material layerhaving a thickness of 30 μm and a volume density of 2.0 g/cc was formed.Finally, the resultant positive electrode current collector on which thepositive electrode active material layer was formed was cut into a shapehaving a width of 50 cm and a length of 300 mm, and a positive electrodeterminal was attached to the exposed portion of the positive electrodecurrent collector, whereby a positive electrode was formed.

Manufacturing of Negative Electrode

97 parts by mass of meso-carbon micro bead present as a negativeelectrode active material, 3 parts by mass of polyvinylidene fluoride(PVdF) present as a binding material were mixed to prepare a negativeelectrode mixture. Then, this negative electrode mixture was dispersedin N-methyl-2-pyrrolidone (NMP) to prepare negative electrode mixtureslurry. This negative electrode mixture slurry was applied to bothsurfaces of a negative electrode current collector formed fromstrip-shaped copper foil having a thickness of 10 μm in such a mannerthat part of the negative electrode current collector was exposed. Then,a dispersion medium of the applied negative electrode mixture slurry wasevaporated and dried, and then compression molding was performed using aroll press. In this manner, a negative electrode active material layerhaving a thickness of 30 μm and a volume density of 1.65 g/cc wasformed. Finally, the resultant negative electrode current collector onwhich the negative electrode active material layer was formed was cutinto a shape having a width of 50 cm and a length of 300 mm, and anegative electrode terminal was attached to the exposed portion of thenegative electrode current collector, whereby a negative electrode wasformed.

Separator

A member, which had a thickness of 16 μm and was obtained by applying apolymeric material supporting an electrolytic solution on both surfacesof a finely porous polyethylene film, was used as a separator. As thepolymeric material, polyvinylidene fluoride (PVdF) having aweight-average molecular weight of 1,000,000 measured in accordance witha gel penetration chromatography method was used, and PVdF was appliedto both surfaces of the finely porous polyethylene film in a thicknessof 1 μm for each surface (total thickness of both surfaces was 2 μm),whereby a separator was obtained.

Electrolytic Solution

As an electrolytic solution, a material obtained by adding the imidesalt compound of Chem. A in a concentration of 1.0 mol/kg with respectto a nonaqueous solvent of ethylene carbonate (EC):ethyl methylcarbonate (EMC)=3:7 (mass ratio) was used.

In addition, the non-fluidic electrolyte layer was formed by making theelectrolytic solution be supported by the polyvinylidene fluoride thatwas applied on the surface of the separator.

Assembling of Battery

The positive electrode and the negative electrode were wound with theseparator interposed therebetween, whereby a wound electrode body wasmanufactured. Subsequently, the wound electrode body was inserted intoan exterior packaging member that was obtained by forming an aluminumlaminated film into a bag shape, 2 g of an electrolytic solution wasinjected into the exterior packaging member, and then the exteriorpackaging member was sealed by thermal fusion in a decompressedatmosphere. Finally, the entirety of the battery was heated to 100° C.and pressed to make part of the electrolytic solution be supported bythe polymeric compound on the surface of the separator and to make theelectrolytic solution gelate. In this manner, the non-fluidicelectrolyte layer was formed on the surface of the separator, whereby alaminated film type battery was manufactured.

In addition, in the battery of Example 1-1, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte (the totalvolume of the non-fluidic electrolyte layer and the fluidic electrolytelayer) was 2.2 vol %. The volume ratio of the non-fluidic electrolyte inthe entirety of the electrolyte was calculated from a SEM image obtainedby using energy dispersive X-ray spectroscopy (SEM-EDX). That is, thecross-sectional area of the non-fluidic electrolyte layer and thecross-sectional area of the fluidic electrolyte layer remained withoutgelation were obtained from a secondary electron image that was obtainedby scanning a cross-section of the electrode body after disassemblingthe battery and taking out the wound electrode body, and the volumeratio was calculated by assuming that the ratio of the cross-section isapproximately the same as the volume ratio.

Example 1-2

A laminated film type battery was manufactured in the same manner asExample 1-1 except that during assembling of the battery, a heatingtemperature when forming the non-fluidic electrolyte layer was set to110° C. In the battery of Example 1-2, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 2.2 vol%.

Example 1-3

A laminated film type battery was manufactured in the same manner asExample 1-1 except that during assembling of the battery, the heatingtemperature when forming the non-fluidic electrolyte layer was set to120° C. In the battery of Example 1-3, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 2.2 vol%.

Examples 1-4 to 1-6

Laminated film type batteries were manufactured in the same manner asExamples 1-1 to 1-3, respectively, except that the thickness of thepolyvinylidene fluoride applied to the surface of the separator was setto 2 μm for each surface (total thickness of both surfaces was 4 μm). Inthe batteries of Examples 1-4 to 1-6, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 4.1 vol%.

Examples 1-7 to 1-9

Laminated film type batteries were manufactured in the same manner asExamples 1-1 to 1-3, respectively, except that the thickness of thepolyvinylidene fluoride applied to the surface of the separator was setto 3 μm for each surface (total thickness of both surfaces was 6 μm). Inthe batteries of Examples 1-7 to 1-9, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 5.6 vol%.

Examples 1-10 to 1-12

Laminated film type batteries were manufactured in the same manner asExamples 1-1 to 1-3, respectively, except that the thickness of thepolyvinylidene fluoride applied to the surface of the separator was setto 8 μm for each surface (total thickness of both surfaces was 16 μm).In the batteries of Examples 1-10 to 1-12, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 10 vol %.

Comparative Example 1-1

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyvinylidene fluoride was not applied to thesurface of the separator.

Examples 1-13 to 1-24

Laminated film type batteries were manufactured in the same manner asExamples 1-1 to 1-12 except that instead of the imide salt compound ofChem. A, hexafluorophosphate (LiPF₆) was used as the electrolyte salt.In the batteries of Examples 1-13 to 1-15, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 2.2 vol%. In the batteries of Examples 1-16 to 1-18, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 4.1 vol%. In the batteries of Examples 1-19 to 1-21, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 5.6 vol%. In the batteries of Examples 1-22 to 1-24, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 10 vol %.

Comparative Example 1-2

A laminated film type battery was manufactured in the same manner asComparative Examples 1-1 except that instead of the imide salt compoundof Chem. A, hexafluorophosphate (LiPF₆) was used as the electrolytesalt.

Evaluation of Battery

(a) High-Temperature Cycle Test

After the batteries of the respective examples and comparative exampleswere subjected to a constant current charge with a charge current of 0.2C in an environment of 23° C. until the battery voltage reached 4.0 V,the batteries were subjected to a constant voltage charge with a batteryvoltage of 4.0 V, and the charge was terminated at a point in time atwhich the charge current reached 0.05 C. Subsequently, the batterieswere subjected to a constant current discharge with a discharge currentof 0.2 C until the battery voltage reached 2.0 V. Two charging anddischarging cycles were performed under the same conditions, and thedischarge capacity at the 2^(nd) cycle was measured.

Subsequently, charging and discharging up to 300 cycles was repeatedunder the same conditions as the above-described charge and dischargeconditions except that the environment temperature was set to 65° C.,and then the discharge capacity at the 300^(th) cycle was measured. Thecapacity retention rate after 300 cycles in a high-temperatureenvironment was calculated by the following expression.

High-temperature capacity retention rate [%]=(discharge capacity at300^(th) cycle/discharge capacity at 2^(nd) cycle)×100

(b) High-Temperature Storage Test

The batteries of the respective examples and comparative examples weresubjected to a constant current charge with a charge current of 0.2 C inan environment of 23° C. until the battery voltage reached 4.0 V, thebatteries were subjected to a constant voltage charge with a batteryvoltage of 4.0 V, and the charge was terminated at a point in time atwhich the charge current reached 0.05 C. Subsequently, the batterieswere subjected to a constant current discharge with a discharge currentof 0.2 C until the battery voltage reached 2.0 V. Two charging anddischarging cycles were performed under the same conditions, and thenthe battery thickness was measured.

Subsequently, the batteries of the respective examples and comparativeexamples were charged with a battery voltage of 4.0 V for three hours inan environment of 23° C., and then the batteries were stored for 24hours in a constant temperature bath of 80° C. while maintaining thecharged state, and then the battery thickness after the storage wasmeasured. A battery thickness increase rate after the high-temperaturestorage was calculated by the following expression.Battery thickness increase rate after high-temperature storage[%]={(battery thickness after high-temperature storage−battery thicknessbefore high-temperature storage)}×100

(c) Discharge Temperature Characteristic Test

After the batteries of the respective examples and comparative exampleswere subjected to a constant current charge with a charge current of 0.2C in an environment of 23° C. until the battery voltage reached 4.0 V,the batteries were subjected to a constant voltage charge with a batteryvoltage of 4.0 V, and the charge was terminated at a point in time atwhich the charge current reached 0.05 C. Subsequently, the batterieswere subjected to a constant current discharge with a discharge currentof 0.2 C until the battery voltage reached 2.0 V. Two charging anddischarging cycles were performed under the same conditions.

Subsequently, after the batteries of the respective examples andcomparative examples were charged for three hours with a battery voltageof 4.0 V in an environment of 23° C., and the batteries were subjectedto a constant current discharge with a discharge current of 0.2 C untilthe battery voltage reached 2.0 V, the discharge capacity (23° C.discharge capacity) at this time was measured. Next, after the batterieswere charged with a battery voltage of 4.0 V for three hours in anenvironment of 23° C., and the batteries were subjected to a constantcurrent discharge with a discharge current 0.2 C in an environment of 0°C. until the battery voltage reached 2.0 V, the discharge capacity (0°C. discharge capacity) at this time was measured. Thedischarge-temperature capacity retention rate was calculated by thefollowing expression.Discharge-temperature capacity retention rate [%]=(0° C. dischargecapacity/23° C. discharge capacity)×100

Evaluation results are shown in Table 1 described below.

TABLE 1 Battery thickness Discharge High- increase temper- PositiveNon-fluidic electrolyte layer temperature rate ature electrodeElectrolyte salt Gelation capacity after high- capacity active Concen-temper- Volume retention temperature retention material trationMolecular ature Thickness ratio rate storage rate Kind Kind [mol/kg]Polymer weight [° C.] [μm] [vol %] [%] [%] [%] Example 1-1 LiFePO₄ Chem.A 1.0 PVdF 1,000,000 100 2 2.2 90 5.6 95 Example 1-2 LiFePO₄ Chem. A 1.0PVdF 1,000,000 110 2 2.2 92 5.2 95 Example 1-3 LiFePO₄ Chem. A 1.0 PVdF1,000,000 120 2 2.2 92 5.3 96 Example 1-4 LiFePO₄ Chem. A 1.0 PVdF1,000,000 100 4 4.1 91 5.0 95 Example 1-5 LiFePO₄ Chem. A 1.0 PVdF1,000,000 110 4 4.1 92 5.0 95 Example 1-6 LiFePO₄ Chem. A 1.0 PVdF1,000,000 120 4 4.1 92 4.8 94 Example 1-7 LiFePO₄ Chem. A 1.0 PVdF1,000,000 100 6 5.6 91 4.8 91 Example 1-8 LiFePO₄ Chem. A 1.0 PVdF1,000,000 110 6 5.6 90 4.8 93 Example 1-9 LiFePO₄ Chem. A 1.0 PVdF1,000,000 120 6 5.6 88 4.7 92 Example 1-10 LiFePO₄ Chem. A 1.0 PVdF1,000,000 100 16  10 82 4.5 70 Example 1-11 LiFePO₄ Chem. A 1.0 PVdF1,000,000 110 16  10 82 4.5 72 Example 1-12 LiFePO₄ Chem. A 1.0 PVdF1,000,000 120 16  10 81 4.5 68 Comparative LiFePO₄ Chem. A 1.0 — — — — 071 8.3 85 Example 1-1 Example 1-13 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 1002 2.2 48 16.5 92 Example 1-14 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 2 2.246 16.3 90 Example 1-15 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 120 2 2.2 4019.4 90 Example 1-16 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 100 4 4.1 55 15.788 Example 1-17 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 4 4.1 55 14.2 89Example 1-18 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 120 4 4.1 42 18.5 88Example 1-19 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 100 6 5.6 56 14.9 85Example 1-20 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 6 5.6 56 13.8 86Example 1-21 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 120 6 5.6 42 18.6 82Example 1-22 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 100 16  10 58 14.1 64Example 1-23 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 16  10 56 14.0 62Example 1-24 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 120 16  10 41 18.4 59Comparative LiFePO₄ LiPF₆ 1.0 — — — — 0 42 22.5 83 Example 1-2

As can be seen from Table 1, among Examples 1-1 to 1-12 and ComparativeExample 1-1 in which the imide salt compound of Chem. A was used as theelectrolyte salt, in Examples 1-1 to 1-12 in which both of thenon-fluidic electrolyte and the fluidic electrolyte were present,battery characteristics were improved. In Examples 1-10 to 1-12 in whichthe volume ratio exceeds 6 vol %, the high-temperature capacityretention rate was improved compared to Comparative Example 1-1 in whichthe non-fluidic electrolyte was not provided, and the battery thicknessincrease rate after the high-temperature storage decreased. In Examples1-1 to 1-9 in which the volume ratio of the non-fluidic electrolyte was6 vol % or less, the high-temperature capacity retention rate and thedischarge temperature capacity retention rate were improved compared toExamples 1-10 to 1-12 and Comparative Example 1-1, and the batterythickness increase rate after the high-temperature storage decreased,and satisfactory results were obtained in all tests. In addition, thehigher the heating temperature during forming the non-fluidicelectrolyte layer was, the further the capacity retention rate in thehigh-temperature environment was improved, and the further the batterythickness increase rate after the high-temperature storage decreased.

This is considered to be because when the non-fluidic electrolyte layeris provided, the separator, which is interposed between the positiveelectrode and the negative electrode, comes into close contact with thepositive electrode and the negative electrode, and thus batteryreactivity is improved. In addition, this is considered to be becausewhen the volume ratio of the non-fluidic electrolyte is set to apredetermined ratio, high ion conductivity due to the fluidicelectrolyte which does not gelate may be obtained while maintaining theclose contact effect, and thus the battery reactivity is improved.

In addition, when the imide salt compound expressed by Chem. A is usedas the electrolyte salt, the electrolyte salt is not likely to bedecomposed even in the high-temperature environment. Therefore, theheating temperature during formation of the non-fluidic electrolytelayer may be raised, and thus even when it is thin, the non-fluidicelectrolyte layer having high bonding strength is formed. As a result,the battery characteristics are improved.

On the other hand, even in the case of Examples 1-13 to 1-24, andComparative Example 1-2 in which lithium hexafluorophosphate was used asthe electrolyte salt, approximately the same tendency as Examples 1-1 to1-12 and Comparative Example 1-1 in which the imide salt of Chem. A wasused was obtained. However, in the case of using lithiumhexafluorophosphate, the discharge temperature capacity retention ratewas approximately constant regardless of the heating temperature duringformation of the non-fluidic electrolyte layer, but the capacityretention rate in the high-temperature environment significantlydecreased as the heating temperature was raised, and thus the batterythickness increase rate after the high-temperature storage increased.This is considered to be because lithium hexafluorophosphate has atendency to be decomposed in a high-temperature environment compared tothe imide salt compound expressed by Chem. A.

Therefore, it was revealed that it is preferable that both of thenon-fluidic electrolyte and the fluidic electrolyte be present, and whenthe volume ratio of the non-fluidic electrolyte with respect to theentirety of the electrolyte is set to 0 to 6 vol %, relatively superiorbattery characteristic may be realized, and this is more preferable. Inaddition, in this case, it was understood that when a predeterminedimide salt compound is used as the electrolyte salt, relatively superiorbattery characteristics may be obtained. Particularly, when theformation of the non-fluidic electrolyte was carried out at a relativelyhigher temperature, the battery characteristics were further improved.In this case, even when the volume ratio of the non-fluidic electrolytewas low, since the battery characteristics were not likely to decrease,and the volume ratio of the fluidic electrolyte increased, the batterycharacteristics were further improved.

Examples 2-1 to 2-7 and Comparative Example 2-1

In Examples 2-1 to 2-7 and Comparative Example 2-1, polyacrylonitrile(PAN) was used as the polymeric material forming the non-fluidicelectrolyte layer, and battery characteristics were evaluated.

Example 2-1

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, and the heating temperature duringformation of the non-fluidic electrolyte layer was set to 80° C. In thebattery of Example 2-1, the volume ratio of the non-fluidic electrolytein the entirety of the electrolyte was 2.2 vol %.

Example 2-2

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, and the heating temperature duringformation of the non-fluidic electrolyte layer was set to 90° C. In thebattery of Example 2-2, the volume ratio of the non-fluidic electrolytein the entirety of the electrolyte was 2.2 vol %.

Example 2-3

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, and the heating temperature duringformation of the non-fluidic electrolyte layer was set to 100° C. In thebattery of Example 2-3, the volume ratio of the non-fluidic electrolytein the entirety of the electrolyte was 2.2 vol %.

Example 2-4

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, the thickness of polyacrylonitrile(PAN) applied to the surface of the separator was set to 2 μm for eachsurface (total thickness of both surfaces was 4 μm), and the heatingtemperature during formation of the non-fluidic electrolyte layer wasset to 90° C. In the battery of Example 2-4, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 4.1 vol%.

Example 2-5

A laminated film type battery was manufactured in the same manner asExample 1-1 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, the thickness of polyacrylonitrile(PAN) applied to the surface of the separator was set to 3 μm for eachsurface (total thickness of both surfaces was 6 μm), and the heatingtemperature during formation of the non-fluidic electrolyte layer wasset to 90° C. In the battery of Example 2-5, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 5.6 vol%.

Examples 2-6 to 2-8

Laminated film type batteries were manufactured in the same manner asExamples 2-1 to 2-3 except that instead of the imide salt compound ofChem. A, hexafluorophosphate (LiPF₆) was used as the electrolyte salt.In the batteries of Examples 2-6 to 2-8, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 2.2 vol%.

Evaluation of Battery

(a) High-Temperature Cycle Test

(b) High-Temperature Storage Test

(c) Discharge Temperature Characteristics Test

Similarly to Example 1-1, the above-described tests were performed withrespect to the respective examples and comparative examples to calculatethe high-temperature capacity retention rate, the battery thicknessincrease rate after high-temperature storage, and the dischargetemperature capacity retention rate, respectively.

Evaluation results are shown in Table 2 described below. In addition, inTable 2, Examples 1-1 to 1-3, and 1-10 to 1-12 in which polyvinylidenefluoride was used as the polymeric material, and Comparative Examples1-1 and 1-2 in which the non-fluidic electrolyte layer was not providedare shown together for reference.

TABLE 2 Battery thickness Discharge High- increase temper- PositiveNon-fluidic electrolyte layer temperature rate ature electrodeElectrolyte salt Gelation capacity after high- capacity active Concen-temper- Volume retention temperature retention material trationMolecular ature Thickness ratio rate storage rate Kind Kind [mol/kg]Polymer weight [° C.] [μm] [vol %] [%] [%] [%] Example 2-1 LiFePO₄ Chem.A 1.0 PAN   700,000  80 2 2.2 84 5.1 92 Example 2-2 LiFePO₄ Chem. A 1.0PAN   700,000  90 2 2.2 85 4.9 94 Example 2-3 LiFePO₄ Chem. A 1.0 PAN  700,000 100 2 2.2 85 5.0 94 Example 2-4 LiFePO₄ Chem. A 1.0 PAN  700,000  90 4 4.1 89 4.5 95 Example 2-5 LiFePO₄ Chem. A 1.0 PAN  700,000  90 6 5.6 86 4.2 94 Example 1-1 LiFePO₄ Chem. A 1.0 PVdF1,000,000 100 2 2.2 90 5.6 95 Example 1-2 LiFePO₄ Chem. A 1.0 PVdF1,000,000 110 2 2.2 92 5.2 95 Example 1-3 LiFePO₄ Chem. A 1.0 PVdF1,000,000 120 2 2.2 92 5.3 96 Comparative LiFePO₄ Chem. A 1.0 — — — — —71 8.3 85 Example 1-1 Example 2-6 LiFePO₄ LiPF₆ 1.0 PAN   700,000  80 22.2 49 16.6 88 Example 2-7 LiFePO₄ LiPF₆ 1.0 PAN   700,000  90 2 2.2 5016.4 91 Example 2-8 LiFePO₄ LiPF₆ 1.0 PAN   700,000 100 2 2.2 48 17.7 91Example 1-10 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 100 2 2.2 48 16.5 92Example 1-11 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 2 2.2 46 16.3 90Example 1-12 LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 120 2 2.2 40 19.4 90Comparative LiFePO₄ LiPF₆ 1.0 — — — — — 42 22.5 83 Example 1-2

As can be seen from Table 2, in a case where the imide salt compoundexpressed by Chem. A was used as the electrolyte salt, in Examples 2-1to 2-5 in which polyacrylonitrile was used as the polymeric material,approximately the same battery characteristics as Examples 1-1 to 1-3 inwhich polyvinylidene fluoride was used as the polymeric material wereobtained. In addition, the battery characteristics were significantlyimproved compared to Comparative Example 1-1 in which the non-fluidicelectrolyte layer was not provided.

In addition, even when lithium hexafluorophosphate was used as theelectrolyte salt, in Examples 2-6 to 2-8 in which polyacrylonitrile wasused as the polymeric material, approximately the same batterycharacteristics as Examples 1-10 to 1-12 in which polyvinylidenefluoride was used as the polymeric material were obtained. In this case,the battery characteristics were also significantly improved compared toComparative Example 1-1 in which the non-fluidic electrolyte layer wasnot provided.

Examples 3-1 to 3-6

In Examples 3-1 to 3-6, the battery characteristics were evaluated bychanging the weight-average molecular weight of the polymeric materialforming the non-fluidic electrolyte layer.

Example 3-1

A laminated film type battery was manufactured in the same manner asExample 1-13 except that polyvinylidene fluoride (PVdF) having aweight-average molecular weight of 350,000 was used as the polymericmaterial applied to the surface of the separator.

Example 3-2

A laminated film type battery was manufactured in the same manner asExample 1-13 except that polyvinylidene fluoride (PVdF) having aweight-average molecular weight of 500,000 was used as the polymericmaterial applied to the surface of the separator.

Example 3-3

A laminated film type battery was manufactured in the same manner asExample 1-13 except that polyvinylidene fluoride (PVdF) having aweight-average molecular weight of 750,000 was used as the polymericmaterial applied to the surface of the separator.

Example 3-4

A laminated film type battery was manufactured in the same manner asExample 1-13.

Example 3-5

A laminated film type battery was manufactured in the same manner asExample 1-13 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 350,000 was used as the polymeric material appliedto the surface of the separator, and the heating temperature duringformation of the non-fluidic electrolyte layer was set to 80° C.

Example 3-6

A laminated film type battery was manufactured in the same manner asExample 1-13 except that polyacrylonitrile (PAN) having a weight-averagemolecular weight of 700,000 was used as the polymeric material appliedto the surface of the separator, and the heating temperature duringformation of the non-fluidic electrolyte layer was set to 80° C.

Evaluation of Battery

(a) High-Temperature Cycle Test

(b) High-Temperature Storage Test

(c) Discharge Temperature Characteristics Test

Similarly to Example 1-1, the above-described tests were performed withrespect to the respective examples and comparative examples to calculatethe high-temperature capacity retention rate, the battery thicknessincrease rate after high-temperature storage, and the dischargetemperature capacity retention rate, respectively.

Evaluation results are shown in Table 3 described below. In addition, inTable 3, Comparative Example 1-2 in which the non-fluidic electrolytelayer was not provided is shown together for reference.

TABLE 3 Battery thickness Discharge High- increase temper- PositiveNon-fluidic electrolyte layer temperature rate ature electrodeElectrolyte salt Gelation capacity after high- capacity active Concen-temper- Volume retention temperature retention material trationMolecular ature Thickness ratio rate storage rate Kind Kind [mol/kg]Polymer weight [° C.] [μm] [vol %] [%] [%] [%] Example 3-1 LiFePO₄ LiPF₆1.0 PVdF   350,000 100 2 2.2 44 19.7 88 Example 3-2 LiFePO₄ LiPF₆ 1.0PVdF   500,000 100 2 2.2 47 16.8 91 Example 3-3 LiFePO₄ LiPF₆ 1.0 PVdF  750,000 100 2 2.2 48 16.6 92 Example 3-4 LiFePO₄ LiPF₆ 1.0 PVdF1,000,000 100 2 2.2 48 16.5 92 Example 3-5 LiFePO₄ LiPF₆ 1.0 PAN  350,000  80 2 2.2 42 21.8 86 Example 3-6 LiFePO₄ LiPF₆ 1.0 PAN  700,000  80 2 2.2 49 16.6 88 Comparative LiFePO₄ LiPF₆ 1.0 — — — — —42 22.5 83 Example 1-2

As can be seen from Table 3, in Examples 3-1 to 3-4 in whichpolyvinylidene fluoride was used as the polymeric material, the furtherthe weight-average molecular weight of the polyvinylidene fluorideincreased, the further the battery characteristics were improved. Thisis considered to be because when the weight-average molecular weight ofthe polyvinylidene fluoride increased, adhesiveness of the non-fluidicelectrolyte layer further increases, and thus the battery reactivitybetween the positive electrode and the negative electrode increases.

In addition, in Examples 3-5 and 3-6 in which polyacrylonitrile was usedas the polymeric material, the same tendency was also observed.

In all of Examples 3-1 to 3-6, the battery characteristics were improvedcompared to Comparative Example 1-2 in which the non-fluidic electrolytelayer was not provided.

Examples 4-1 to 4-6

In Examples 4-1 to 4-6, a kind of positive electrode active material anda kind of electrolyte salt were changed and the non-fluidic electrolytelayer was formed in such a manner that the volume ratio thereof wasapproximately constant, and then the battery characteristics wereevaluated.

Example 4-1

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of the imide salt compound of Chem. A,the imide salt compound of Chem. B was used as the electrolyte salt. Inthe battery of Example 4-1, the volume ratio of the non-fluidicelectrolyte in the entirety of the electrolyte was 4.1 vol %.

Example 4-2

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of the imide salt compound of Chem. A,the imide salt compound of Chem. C was used as the electrolyte salt. Inthe battery of Example 4-2, the volume ratio of the non-fluidicelectrolyte in the entirety of the electrolyte was 4.1 vol %.

Example 4-3

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of lithium iron phosphate (LiFePO₄),lithium iron manganese phosphate (LiFe_(0.75)Mn_(0.25)PO₄) was used asthe positive electrode active material. In the battery of Example 4-3,the volume ratio of the non-fluidic electrolyte in the entirety of theelectrolyte was 4.1 vol %.

Example 4-4

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of lithium iron phosphate (LiFePO₄),lithium manganese phosphate (LiMnPO₄) was used as the positive electrodeactive material. In the battery of Example 4-4, the volume ratio of thenon-fluidic electrolyte in the entirety of the electrolyte was 4.1 vol%.

Example 4-5

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of lithium iron phosphate (LiFePO₄),lithium cobaltate (LiCoO₂) was used as the positive electrode activematerial, and the layer thickness was set to 1 μm for each surface(total thickness of both surfaces was 2 μm). In the battery of Example4-5, the volume ratio of the non-fluidic electrolyte in the entirety ofthe electrolyte was 4.2 vol %. Since a volume density of the positiveelectrode active layer varies (increases) when lithium cobaltate(LiCoO₂) is used as the positive electrode active material, thethickness of the non-fluidic electrolyte layer was adjusted such thatthe volume ratio of the non-fluidic electrolyte layer is approximatelythe same as Example 4-1.

Example 4-6

A laminated film type battery was manufactured in the same manner asExample 1-5 except that instead of lithium iron phosphate (LiFePO₄),lithium nickel cobalt manganese composite oxide(LiNi_(0.33)Co_(0.33)Mn_(0.33)O₂) was used as the positive electrodeactive material, and the layer thickness was set to 1 μm for eachsurface (total thickness of both surfaces was 2 μm). In the battery ofExample 4-6, the volume ratio of the non-fluidic electrolyte in theentirety of the electrolyte was 4.2 vol %.

Evaluation of Battery

(a) High-Temperature Cycle Test

(b) High-Temperature Storage Test

(c) Discharge Temperature Characteristics Test

Similarly to Example 1-1, the above-described tests were performed withrespect to the respective examples and comparative examples to calculatethe high-temperature capacity retention rate, the battery thicknessincrease rate after high-temperature storage, and the dischargetemperature capacity retention rate, respectively. In addition, inExamples 4-5 and 4-6 in which a cobalt-based positive electrode activematerial having a layered structure was used, the upper limit voltageduring charging was set to 4.2 V, and a discharge termination voltagewas set to 3.0 V. Otherwise, the above-described tests were carried outin the same manner as Example 1-1.

Evaluation results are shown in Table 4 described below. In addition, inTable 4, Examples 1-5 and 1-17, and Comparative Example 1-1 in which thenon-fluidic electrolyte layer was not provided are shown together forreference.

TABLE 4 High- Battery temper- thickness Discharge ature increase temper-Positive Non-fluidic electrolyte layer capacity rate ature electrodeElectrolyte salt Gelation reten- after high- capacity active Concen-temper- Thick- Volume tion temperature retention material trationMolecular ature ness ratio rate storage rate Kind Kind [mol/kg] Polymerweight [° C.] [μm] [vol %] [%] [%] [%] Example 1-5 LiFePO₄ Chem. A 1.0PVdF 1,000,000 110 4 4.1 92 5.0 95 Example 4-1 LiFePO₄ Chem. B 1.0 PVdF1,000,000 110 4 4.1 91 4.6 92 Example 4-2 LiFePO₄ Chem. C 1.0 PVdF1,000,000 110 4 4.1 82 6.1 88 Example 4-3 LiFe_(0.75)Mn_(0.25)PO₄ Chem.A 1.0 PVdF 1,000,000 110 4 4.1 88 5.9 90 Example 4-4 LiMnPO₄ Chem. A 1.0PVdF 1,000,000 110 4 4.1 86 6.3 86 Example 4-5 LiCoO₂ Chem. A 1.0 PVdF1,000,000 110 2 4.2 72 8.4 83 Example 4-6LiNi_(0.33)Co_(0.33)Mn_(0.33)O₂ Chem. A 1.0 PVdF 1,000,000 110 2 4.2 788.7 87 Example LiFePO₄ LiPF₆ 1.0 PVdF 1,000,000 110 4 4.1 55 14.2 891-17 Comparative LiFePO₄ Chem. A 1.0 — — — — — 71 8.3 85 Example 1-1

As can be seen from Table 4, in Examples 4-1, 4-2, and 1-5 in whichlithium iron phosphate (LiFePO₄) was used as the positive electrodeactive material, in a case of using an imide salt in which at least oneof the substituent groups Z in Chem. 1 is a fluorine atom, the batterycharacteristics were significantly improved.

In addition, in Examples 4-3 to 4-6 and 1-5 in which the imide saltcompound expressed by Chem. A was used as the electrolyte salt, in acase of using a material having an olivine structure as the positiveelectrode active material, the battery characteristics weresignificantly improved. Among these, the battery characteristics wereimproved in a case of using lithium manganese iron phosphate in whichiron (Fe) and manganese (Mn) were contained as a transition metalcompared to lithium manganese phosphate in which manganese (Mn) wascontained as a transition metal, and in a case of using lithium ironphosphate containing only iron (Fe) was contained as a transition metal,the battery characteristics were further improved. That is, the largerthe content of iron as a transition metal in a material having anolivine structure was, the better the battery characteristics wereobtained.

In all of Examples 4-1 to 4-6, the battery characteristics were improvedcompared to Comparative Example 1-1 in which the non-fluidic electrolytelayer was not provided.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present subjectmatter and without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by the appendedclaims.

The invention is claimed as follows:
 1. A battery comprising: a positiveelectrode including a positive electrode active material; a negativeelectrode including a negative electrode active material; a separator; afluidic electrolyte; and a polymer layer including a polymeric material;wherein at least a portion of the polymer layer is provided between theseparator and at least one of the positive electrode active material andthe negative electrode active material; wherein the fluidic electrolyteis provided in at least a void portion of at least one of the positiveelectrode and the negative electrode; and wherein the polymeric materialis equal to or less than 0.3% by volume and greater than 0% by volumewith respect to a total void volume of at least one of the positiveelectrode, the negative electrode and the separator.
 2. The batteryaccording to claim 1, wherein the polymeric material is at least one ofpolyvinylidene fluoride and polyacrylonitrile.
 3. The battery accordingto claim 1, wherein a thickness of the polymer layer on at least oneside of the separator is from 1 um to 8 um.
 4. The battery according toclaim 3, wherein the thickness is from 1 um to 3 um.
 5. The batteryaccording to claim 1, wherein the polymer layer includes a non-fluidicelectrolyte.
 6. The battery according to claim 5, wherein thenon-fluidic electrolyte includes an electrolytic solution including asolvent and an electrolyte salt, and wherein the electrolytic solutionin the non-fluidic electrolyte is 90 to 99% by mass.
 7. The batteryaccording to claim 5, wherein the non-fluidic electrolyte is equal to orless than 6% by volume with respect to a total volume of the fluidicelectrolyte and the non-fluidic electrolyte.
 8. The battery according toclaim 1, wherein the fluidic electrolyte includes an electrolyte salt,and wherein the electrolyte salt includes an imide salt compoundexpressed by Chem. 1 below:M⁺[(ZY)₂N]⁻  (Chem. 1) wherein M⁺ represents a monovalent cation, Yrepresents SO₂ or CO, and Z represents a fluorine atom or apolymerizable functional group.
 9. The battery according to claim 8,wherein at least one Z is a fluorine atom.
 10. The battery according toclaim 9, wherein the electrolyte salt includes at least one of lithiumbis(fluorosulfonyl)imide, lithium(fluorosulfonyl)(trifluoromethylsulfonyl)imide, and lithiumbis(trifluoromethyl sulfonyl)imide.
 11. The battery according to claim1, wherein the positive electrode active material includes a lithiumcomposite oxide expressed by Chem. II below:Li_(e)Ni_((1-d-e))Mn_(d)M2_(e)O_((1-f))X_(g)  (Chem. II) wherein M2represents at least one element selected from group II to group XV notincluding nickel (Ni) and manganese (Mn), X represents at least oneelement selected from group XVI and group XVII not including oxygen (O),and d, e, f, and g represent values within ranges of 0≦d≦1.0, 0≦e≦1.0,−0.10≦f≦0.20, and 0≦g≦0.2.
 12. The battery according to claim 1, whereinthe positive electrode active material includes a lithium compositephosphate expressed by Chem. III below:Li_(h)M3PO₄  (Chem. III) wherein M3 represents at least one elementselected from the group consisting of cobalt (Co), manganese (Mn), iron(Fe), nickel (Ni), magnesium (Mg), aluminum (Al), boron (B), titanium(Ti), vanadium (V), niobium (Nb), copper (Cu), zinc (Zn), molybdenum(Mo), calcium (Ca), strontium (Sr), tungsten (W), and zirconium (Zr),and h represents a value within a range of 0.9≦h≦1.1.
 13. The batteryaccording to claim 1, wherein the positive electrode active materialincludes a lithium composite oxide expressed by Chem. IV below:Li_(i)Mn_((1-j-k))Ni_(j)M4_(k)O_((1-m))F_(n)  (Chem. IV) wherein M4represents at least one element selected from the group consisting ofcobalt (Co), magnesium (Mg), aluminum (Al), boron (B), titanium (Ti),vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc (Zn),zirconium (Zr), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr),and tungsten (W), and i, j, k, m, and n represent values within rangesof 0.8≦i≦1.2, 0<j<0.5, 0≦k≦0.5, j+k<1, −0.1≦m≦0.2, and 0≦n≦0.1.
 14. Thebattery according to claim 1, wherein the positive electrode activematerial includes a lithium composite oxide expressed by Chem. V below:Li_(o)Ni_((1-p))M5_(p)O_((1-q))F_(r)  (Chem. V) wherein M5 represents atleast one element selected from the group consisting of cobalt (Co),manganese (Mn), magnesium (Mg), aluminum (Al), boron (B), titanium (Ti),vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc (Zn),molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), and tungsten(W), and o, p, q, and r represent values within ranges of 0.8≦o≦1.2,0.005≦p≦5, −0.1≦q≦0.2, 0≦r≦0.1.
 15. The battery according to claim 1,wherein the negative electrode active material includes a materialcapable of occluding and emitting lithium ions.
 16. The batteryaccording to claim 15, wherein the negative electrode active materialincludes at least one of a non-graphitization carbon, aneasy-graphitization carbon, a graphite, a pyrolytic carbon, a coke, aglassy carbon, an organic polymeric material, a carbon fiber, and anactivated charcoal.
 17. The battery according to claim 15, wherein thenegative electrode active material includes a constituent selected fromthe group consisting of magnesium (Mg), boron (B), aluminum (Al),titanium (Ti), gallium (Ga), indium (In), silicon (Si), germanium (Ge),tin (Sn), lead (Pb), bismuth (Bi), cadmium (Cd), silver (Ag), zinc (Zn),hafnium (Hf), zirconium (Zr), yttrium (Y), palladium (Pd), platinum(Pt), nickel (Ni), copper (Cu), iron (Fe), cobalt (Co), manganese (Mn),antimony (Sb), chromium (Cr), oxygen (O), carbon (C), niobium (Nb),molybdenum (Mo), phosphorous (P) and combinations thereof.
 18. Thebattery according to claim 15, wherein the negative electrode activematerial includes a SnCoC-containing material that includes tin (Sn),cobalt (Co), and carbon (C).
 19. The battery according to claim 18,wherein a content of carbon (C) is 9.9 mass % to 29.7 mass %, and aratio of cobalt (Co) on a basis of a sum of tin (Sn) and cobalt (Co) is30 mass % to 70 mass %.
 20. A battery comprising: a positive electrodeincluding a positive electrode active material; a negative electrodeincluding a negative electrode active material; a separator having afirst surface and a second surface; a fluidic electrolyte; a firstnon-fluidic electrolyte formed on the first surface of the separator;and a second non-fluidic electrolyte formed on the second surface of theseparator, wherein each of the first non-fluidic electrolyte and thesecond non-fluidic electrolyte includes a polymeric material, and atleast a portion of the first non-fluidic electrolyte is configured tocontact with the positive electrode and at least a portion of the secondnon-fluidic electrolyte is configured to contact with the negativeelectrode; wherein the fluidic electrolyte is provided in at least avoid portion of at least one of the positive electrode and the negativeelectrode, and wherein the polymeric material is equal to or less than0.3% by volume and greater than 0% by volume with respect to a totalvoid volume of at least one of the positive electrode, the negativeelectrode and the separator.
 21. The battery according to claim 20,wherein the polymeric material is at least one of polyvinylidenefluoride and polyacrylonitrile.
 22. The battery according to claim 20,wherein a thickness of at least one of the first non-fluidic electrolyteand the second non-fluidic electrolyte is from 1 um to 8 um.
 23. Thebattery according to claim 22, wherein the thickness is from 1 um to 3um.
 24. The battery according to claim 20, wherein the fluidicelectrolyte includes an electrolyte salt, and wherein the electrolytesalt includes an imide salt compound expressed by Chem. 1 below:M⁺[(ZY)₂N]⁻  (Chem. 1) wherein M⁺ represents a monovalent cation, Yrepresents SO₂ or CO, and Z represents a fluorine atom or apolymerizable functional group.
 25. The battery according to claim 24,wherein the electrolyte salt includes at least one of lithiumbis(fluorosulfonyl)imide, lithium(fluorosulfonyl)(trifluoromethylsulfonyl)imide, and lithiumbis(trifluoromethyl sulfonyl)imide.
 26. The battery according to claim22, wherein the fluidic electrolyte includes an electrolyte salt, andwherein the electrolyte salt includes an imide salt compound expressedby Chem. 1 below:M⁺[(ZY)₂N]⁻  (Chem. 1) wherein M⁺ represents a monovalent cation, Yrepresents SO₂ or CO, and Z represents a fluorine atom or apolymerizable functional group.
 27. The battery according to claim 23,wherein the fluidic electrolyte includes an electrolyte salt, andwherein the electrolyte salt includes an imide salt compound expressedby Chem. 1 below:M⁺[(ZY)₂N]⁻  (Chem. 1) wherein M⁺ represents a monovalent cation, Yrepresents SO₂ or CO, and Z represents a fluorine atom or apolymerizable functional group.
 28. The battery according to claim 20,wherein the negative electrode active material includes a materialcapable of occluding and emitting lithium ions.
 29. The batteryaccording to claim 1, wherein a weight-average molecular weight of thepolymeric material is 500,000 or more.
 30. The battery according toclaim 20, wherein a weight-average molecular weight of the polymericmaterial is 500,000 or more.